Honda CIVIC 10G 2016 Engine Mechanical System Page 1

Engine Configuration
Cylinder Arrangement/Firing Order: 1342
Engine Rotation: Clockwise
Engine Configuration 2925 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/...
1 of 1 12/20/2018 6:53 AM
cardiagn.com

Contents Summary of Engine Mechanical System

  • Page 1Engine Configuration Cylinder Arrangement/Firing Order: 1-3-4-2 Engine Rotation: Clockwise cardiagn.com
  • Page 2Engine Configuration cardiagn.com
  • Page 3Engine Configuration cardiagn.com
  • Page 4Block and Piston Inspection 1. Crankshaft - Remove 2. Piston - Remove 3. Engine Block - Inspect 1. Check the top of the engine block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.002 in) max. cardiagn.com
  • Page 52. Measure the wear and taper in direction Y and X at three levels inside each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the engine block is being rebored, check the piston-to-cylinder bore clearance. Cylinder Bore Siz
  • Page 62. Check the pistons for distortion or cracks. 3. Measure the piston skirt diameter at a point 10 mm (0.39 in) (59B) or 11 mm (0.43 in) (5PA) from the bottom of the skirt. Piston Skirt Diameter Standard (New): 72.972-72.979 mm (2.87291-2.87318 in) Service Limit: 72.962 mm (2.87251 in) cardiagn.com 4
  • Page 7Block and Piston Inspection NOTE: Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine. 1. Crankshaft - Remove 2. Piston - Remove 3. Block and Piston - Inspect 1. Check the pistons for distortion or cracks. Measure the piston skirt diameter at a point 11 mm (0.43 in)
  • Page 82. Measure the wear and taper in direction X and Y at three levels inside each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the engine block is being rebored, check the piston-to-cylinder bore clearance. Cylinder Bore Siz
  • Page 93. Hone any cored or scratched cylinder bores if needed. cardiagn.com 4. Check the top of the engine block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.002 in) max.
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  • Page 115. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near, or exceeds the service limit, inspect the piston and the cylinder bore for excessive wear. Piston-to-Cylinder Bore Clearance Standard (New): 0.020-0.040 mm (0.00079-0.00157 in) Service L
  • Page 12Cam Chain Auto-Tensioner Removal and Installation 1. Right Front Wheel - Remove 2. Engine Undercover - Remove 3. Chain Case Cover - Remove cardiagn.com 4. Cam Chain Auto-Tensioner - Remove 1. Turn the crankshaft counterclockwise to compress the cam chain auto-tensioner.
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  • Page 142. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the cam chain auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin. NOTE: If the holes in the lock and the cam chain auto-tensioner do not a
  • Page 151. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the cam chain auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E)
  • Page 163. Remove the pin (A) from the cam chain auto-tensioner. cardiagn.com
  • Page 172. Chain Case Cover - Install 1. Apply liquid gasket to the cam chain case mating surface of the chain case cover, and to the inside edge of the threaded bolt holes. 2. Install the chain case cover. cardiagn.com 3. Engine Undercover - Install 4. Right Front Wheel - Install
  • Page 18Cam Chain Auto-Tensioner Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 19cardiagn.co
  • Page 20Detailed information, notes, and precautions 1. Right Front Wheel - Remove 2. Engine Undercover - Remove NOTE: Remove the necessary part(s). 3. Chain Case Cover - Remove 4. Cam Chain Auto-Tensioner - Remove 1. Turn the crankshaft counterclockwise to compress the cam chain auto-tensioner. cardiagn.co
  • Page 21NOTE: Check the cam chain auto-tensioner filter for damage. If filter is damaged, replace it. NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 22cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 1. Cam Chain Auto-Tensioner Filter - Install 2. Cam Chain Auto-Tensioner - Install
  • Page 231. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the cam chain auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E)
  • Page 24Cam Chain Auto-Tensioner Removal and Installation 1. Right Front Wheel - Remove 2. Engine Undercover - Remove 3. Chain Case Cover - Remove cardiagn.com 4. Cam Chain Auto-Tensioner - Remove 1. Turn the crankshaft counterclockwise to compress the cam chain auto-tensioner.
  • Page 252. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the cam chain auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin. NOTE: If the holes in the lock and the auto-tensioner do not align, cont
  • Page 261. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the cam chain auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E)
  • Page 274. Remove the pin (A) from the cam chain auto-tensioner. 2. Chain Case Cover - Install cardiagn.com
  • Page 281. Apply liquid gasket to the cam chain case mating surface of the chain case cover, and to the inside edge of the threaded bolt holes. 2. Install the chain case cover. cardiagn.com 3. Engine Undercover - Install 4. Right Front Wheel - Install
  • Page 29Cam Chain Inspection 1. Right Front Wheel - Remove 2. Engine Undercover - Remove 3. Chain Case Cover - Remove cardiagn.com 4. Cam Chain - Inspect
  • Page 301. Measure the length of the cam chain auto-tensioner rod. Cam Chain Auto-Tensioner Rod Length Standard (New): 21.9 mm (0.862 in) Service Limit: 25.8 mm (1.016 in) 2. If the length is over the service limit, replace the cam chain. When replacing, check the teeth on the cam chain drive sprocket, VTC
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  • Page 32Cam Chain Inspection 1. Right Front Wheel - Remove 2. Engine Undercover - Remove NOTE: Remove the necessary part(s). 3. Chain Case Cover - Remove 4. Cam Chain - Inspect 1. Measure the length of the cam chain auto-tensioner rod. cardiagn.com Cam Chain Auto-Tensioner Rod Length Service Limit: 26.3 mm
  • Page 33Cam Chain Inspection 1. Right Front Wheel - Remove 2. Engine Undercover - Remove 3. Chain Case Cover - Remove cardiagn.com 4. Cam Chain - Inspect 1. Measure the length of the cam chain auto-tensioner rod. Cam Chain Auto-Tensioner Rod Length Service Limit: 26.3 mm (1.035 in) 2. If the length is over
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  • Page 355. Chain Case Cover - Install 1. Apply liquid gasket to the cam chain case mating surface of the chain case cover and to the inside edge of the threaded bolt holes. 2. Install the chain case cover. cardiagn.com 6. Engine Undercover - Install 7. Right Front Wheel - Install
  • Page 36Cam Chain Oil Jet Inspection 1. Cam Chain Oil Jet - Remove 2. Cam Chain Oil Jet - Inspection 1. Make sure that a 0.6 mm (1/32 in) diameter drill bit will go through the nozzle hole (A) (0.8 mm (0.031 in) diameter). cardiagn.com 3. All Removed Parts - Install 1. Install the parts in the reverse order
  • Page 37Cam Chain Oil Jet Removal and Installation NOTE: How to read the torque specifications. Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine. 1. Cam Chain Case - Remove 2. Cam Chain Oil Jet - Remove cardiagn.com 3. All Removed Parts - Install 1. Install the parts in t
  • Page 38Cam Chain Removal and Installation Special Tool Required Image Description/Tool Number Camshaft Lock Pin Set 07AAB-RWCA120 cardiagn.com NOTE: Keep the cam chain away from magnetic fields. 1. Right Front Wheel - Remove 2. Engine Undercover - Remove 3. Drive Belt - Remove 4. No. 1 Piston at Top Dead C
  • Page 391. Turn the crankshaft so its white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. 5. Crankshaft Pulley - Remove cardiagn.com 6. Drive Belt Auto-Tensioner - Remove 7. Dipstick - Remove 8. Cylinder Head Cover - Remove 9. Expansion Tank - Move NOTE: Do not disco
  • Page 401. Disconnect the connector (A). 2. Remove the harness clamp (B). 12.VTC Oil Control Solenoid Valve A - Remove cardiagn.com 13.Cam Chain Case - Remove 14.No. 1 Piston at Top Dead Center - Set (Cam Side)
  • Page 411. Set the No. 1 piston at top dead center (TDC). The "UP" mark (C) on VTC actuator A should be at the top. Align the TDC marks (D) on VTC actuator A and VTC actuator B. NOTE: If the marks are not aligned, rotate the crankshaft 360 degrees, and recheck VTC actuator A and VTC actuator B marks. 15.Cam
  • Page 423. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the cam chain auto-tensioner (B). 4. Insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. 5. Turn the crankshaft clockwise to secure the pin. NOTE: If the holes in the lock and the cam chain auto-tensioner do not
  • Page 436. Remove the cam chain auto-tensioner (A) and the cam chain auto-tensioner filter (B). NOTE: Check the cam chain auto-tensioner filter for damage. If filter is damaged, replace it. 7. Remove the crankshaft pulley. cardiagn.com 16.Cam Chain Guide B - Remove 17.Cam Chain - Remove
  • Page 441. Remove the cam chain guide (A), the cam chain tensioner arm (B), and the cam chain tensioner sub arm (C). 2. Remove the cam chain. cardiagn.com NOTE: Keep the cam chain away from magnetic fields. 1. No. 1 Piston at Top Dead Center - Set (Crank Side) 1. Set the crankshaft to top dead center (TDC).
  • Page 451. Set the No. 1 piston at top dead center (TDC). The "UP" mark (C) on VTC actuator A should be at the top and align the TDC marks (D) on VTC actuator A and VTC actuator B. 3. Camshaft Lock Pin Set - Install 1. Insert the camshaft lock pin set to camshaft maintenance holes. cardiagn.com 4. Cam Chain
  • Page 46Intake 2. Install the cam chain on VTC actuator A and VTC actuator B with the punch marks (A) aligned with the center of the colored link plates (B). cardiagn.com Exhaust 5. Cam Chain Tensioner Arm, Cam Chain Tensioner Sub Arm, and Cam Chain Guide - Install
  • Page 471. Install the cam chain guide (A), the cam chain tensioner arm (B), and the cam chain tensioner sub arm (C). cardiagn.com 6. Cam Chain Guide B - Install 7. Camshaft Lock Pin Set - Remove
  • Page 481. Remove the camshaft lock pin set from the camshaft maintenance holes. 8. Cam Chain Auto-Tensioner - Install 1. Compress the cam chain auto-tensioner when replacing the cardiagn.com cam chain. Remove the pin (A) from the cam chain auto-tensioner that was installed during removal. Turn the plate (B
  • Page 492. Install the cam chain auto-tensioner filter (A) and the cam chain auto-tensioner (B). cardiagn.com 3. Remove the pin (A) from the cam chain auto-tensioner. 9. Cam Chain Case - Install
  • Page 501. Check the pulley end crankshaft oil seal for damage. If the oil seal is damaged, replace the pulley end crankshaft oil seal. 2. Apply liquid gasket to the engine block, the cylinder head, and the oil pan mating surface of the cam chain case and to the inside edge of the threaded bolt holes. 3. Se
  • Page 511. Install the harness clamp (A). 2. Connect the connector (B). 12.Side Engine Mount - Install cardiagn.com 13.Expansion Tank - Install 14.Cylinder Head Cover - Install 15.Dipstick - Install 16.Drive Belt Auto-Tensioner - Install 17.Crankshaft Pulley - Install 18.Drive Belt - Install 19.Engine Under
  • Page 5221.Ignition Timing - Inspect cardiagn.com
  • Page 53Cam Chain Removal and Installation Special Tool Required Image Description/Tool Number Camshaft Lock Pin Set 07AAB-RWCA120 cardiagn.com NOTE: Where icon is shown, click for further information. Keep the cam chain away from magnetic fields. When removing the cam chain, turn the crankshaft to align No
  • Page 542 cardiagn.com
  • Page 553 Replace cardiagn.com
  • Page 56cardiagn.com Detailed information, notes, and precautions 1. Right Front Wheel - Remove 2. Engine Undercover - Remove NOTE: Remove the necessary part(s). 3. Drive Belt - Remove
  • Page 574. Crankshaft Pulley - Remove 1. Turn the crankshaft so its white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case, then remove the crankshaft pulley. cardiagn.com 5. Drive Belt Auto-Tensioner - Remove 6. Drive Belt Idler Pulley - Remove 7. Cylinder Head Cover -
  • Page 5814.Side Engine Mount Bracket - Remove 15.Cam Chain Case - Remove 16.Cam Chain Auto-Tensioner - Remove 1. Set the No. 1 piston at top dead center (TDC). The "UP" mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuator A and VTC actuator B. The TDC marks (C) on VTC act
  • Page 594. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B). 5. Insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. 6. Turn the crankshaft clockwise to secure the pin. NOTE: If the holes in the lock and the auto-tensioner do not align, continue to r
  • Page 6020.Cam Chain Guide B - Remove 21.Cam Chain Guide A - Remove 22.Cam Chain Tensioner Sub Arm - Remove 23.Cam Chain Tensioner Arm - Remove 24.Cam Chain - Remove cardiagn.com NOTE: Where icon is shown, click for further information. Keep the cam chain away from magnetic fields. When installing the cam c
  • Page 61cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 2
  • Page 62cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 3
  • Page 63cardiagn.com Torque: N·m (kgf·m, lbf·ft) 1. Cam Chain - Install
  • Page 641. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block. cardiagn.com 2. Set the No. 1 piston at top dead center (TDC). The "UP'' mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuato
  • Page 653. Insert the camshaft lock pin set to the camshaft maintenance hole. cardiagn.com 4. Install the cam chain on the crankshaft sprocket with the colored link plate (A) aligned with the mark (B) on the crankshaft sprocket.
  • Page 665. Install the cam chain on VTC actuator A and VTC actuator B with the punch marks (A) aligned with the center of the colored link plates (B). 2. Cam Chain Guide A - Install cardiagn.com 3. Cam Chain Tensioner Arm - Install 4. Cam Chain Tensioner Sub Arm - Install 5. Cam Chain Guide B - Install 6. S
  • Page 671. Remove the camshaft lock pin set from the camshaft maintenance hole. 2. Compress the cam chain auto-tensioner when replacing the cardiagn.com cam chain. Remove the pin (A) from the cam chain auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock
  • Page 683. Install the cam chain auto-tensioner. 4. Remove the pin (A) from the cam chain auto-tensioner. 10.Cam Chain Case - Install cardiagn.com 1. Check the pulley end crankshaft oil seal for damage. If the oil seal is damaged, replace the pulley end crankshaft oil seal. 2. Apply liquid gasket to the cyl
  • Page 6916.Rocker Arm Oil Control Valve - Install 17.Side Engine Mount - Install 18.Cylinder Head Cover - Install 19.Drive Belt Idler Pulley - Install 20.Drive Belt Auto-Tensioner - Install cardiagn.com 21.Crankshaft Pulley - Install 22.Drive Belt - Install 23.Engine Undercover - Install 24.Right Front Whee
  • Page 70Cam Chain Removal and Installation Special Tool Required Image Description/Tool Number Camshaft Lock Pin Set 07AAB-RWCA120 cardiagn.com NOTE: Keep the cam chain away from magnetic fields. 1. Right Front Wheel - Remove 2. Engine Undercover - Remove 3. Drive Belt - Remove 4. No. 1 Piston at Top Dead C
  • Page 711. Turn the crankshaft so its white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. cardiagn.com 5. Crankshaft Pulley - Remove 6. Cylinder Head Cover - Remove 7. Side Engine Mount - Remove 8. Rocker Arm Oil Control Valve - Remove 9. VTC Oil Control Solenoid Val
  • Page 721. Remove the harness holder (A) and the harness bracket (B). cardiagn.com 11. Cam Chain Case - Remove 1. Remove the cam chain case (A), the key (B), the spacer (C), and O-rings (D). 12.No. 1 Piston at Top Dead Center - Set (Cam Side)
  • Page 731. Set the No. 1 piston at top dead center (TDC). The "UP" mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuator A and VTC actuator B. The TDC marks (C) on VTC actuator B should line up with the top edge of the head (D). NOTE: If the marks are not aligned, rotate t
  • Page 743. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B). 4. Insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. 5. Turn the crankshaft clockwise to secure the pin. NOTE: If the holes in the lock and the auto-tensioner do not align, continue to r
  • Page 756. Remove the cam chain auto-tensioner (A). 7. Remove the cam chain auto-tensioner filter (B) from the cam chain auto-tensioner. NOTE: Check the cam chain auto-tensioner filter for damage. If filter is damaged, replace it. 8. Remove the crankshaft pulley. cardiagn.com 14.Cam Chain Guide B - Remove 1
  • Page 761. Remove cam chain guide A, the cam chain tensioner arm (B), and the cam chain tensioner sub arm (C). 2. Remove the cam chain. cardiagn.com NOTE: Keep the cam chain away from magnetic fields. 1. No. 1 Piston at Top Dead Center - Set (Crank Side) 1. Set the crankshaft to top dead center (TDC). Align
  • Page 771. Set the No. 1 piston at top dead center (TDC). The "UP'' mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuator A and VTC actuator B. The TDC marks (C) on VTC actuator B should line up with the top edge of the head (D). 3. Camshaft Lock Pin Set - Insert 1. Insert
  • Page 781. Install the cam chain on the crankshaft sprocket with the colored link plate (A) aligned with the mark (B) on the crankshaft sprocket. cardiagn.com 2. Install the cam chain on VTC actuator A and VTC actuator B with the punch marks (A) aligned with the center of the colored link plates (B). 5. Cam
  • Page 791. Install cam chain guide A, the cam chain tensioner arm (B), and the cam chain tensioner sub arm (C). cardiagn.com 6. Cam Chain Guide B - Install 7. Camshaft Lock Pin Set - Remove
  • Page 801. Remove the camshaft lock pin set from camshaft maintenance hole. 8. Cam Chain Auto-Tensioner - Install cardiagn.com 1. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the cam chain auto-tensioner that was installed during removal. Turn the plate (B) cou
  • Page 812. Install the cam chain auto-tensioner filter (A) to the cam chain auto-tensioner (B). 3. Install the cam chain auto-tensioner. cardiagn.com 4. Remove the pin (A) from the cam chain auto-tensioner. 9. Cam Chain Case - Install
  • Page 821. Check the pulley end crankshaft oil seal for damage. If the oil seal is damaged, replace the pulley end crankshaft oil seal. 2. Apply liquid gasket to the cylinder head, the engine block and the oil pan mating surface of the cam chain case and to the inside edge of the threaded bolt holes. 3. Ins
  • Page 831. Install the harness bracket (A) and the harness holder (B). cardiagn.com 11. VTC Oil Control Solenoid Valve A - Install 12.Rocker Arm Oil Control Valve - Install 13.Side Engine Mount - Install 14.Cylinder Head Cover - Install 15.Crankshaft Pulley - Install 16.Drive Belt - Install 17.Engine Underc
  • Page 8419.Ignition Timing - Inspect cardiagn.com
  • Page 85Camshaft and VTC Actuator Removal, Installation, and Inspection 1. Fuel Pressure - Relieve 2. Air Cleaner - Remove 3. Intake Air Duct - Remove 4. High Pressure Fuel Pump - Remove 5. EVAP Canister Purge Valve - Remove cardiagn.com 6. CMP Sensor A/B - Remove 7. High Pressure Fuel Pump Base - Remove 1.
  • Page 864. Disconnect the heater hoses (A). 5. Remove the heater hose bracket (B) and the harness holder bracket (C). cardiagn.com 6. Remove the cam holder cover (A).
  • Page 877. Remove the high pressure fuel pump base (A). cardiagn.com 8. Cam Chain - Remove NOTE: After cam chain removal, reinstall the cam chain guide B mounting bolts to the specified torque, if remove VTC actuator A/B. 9. Adjusting Screw - Loosen 1. Loosen the locknuts and the adjusting screws (A). 10.VT
  • Page 88NOTE: If remove the VTC actuator A/B, do this procedure. 1. Hold the intake camshaft with an open-end wrench, then loosen the VTC actuator A mounting bolt. cardiagn.com 2. Hold the exhaust camshaft with an open-end wrench, then loosen the VTC actuator B mounting bolt. 11. Camshaft - Remove
  • Page 891. Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time. 2. Remove the camshaft holders (A), cam chain guide B, the intake camshaft (C), and the exhaust camshaft (D). cardiagn.com 12.VTC Actuator A/B - Remove
  • Page 90NOTE: If remove the VTC actuator A/B, do this procedure. VTC Actuator A and VTC Actuator B - Inspection 1. VTC Actuator A/B - Inspect cardiagn.com 1. Check that VTC actuator A/B is locked by turning it. If it is not locked, replace VTC actuator A/B.
  • Page 912. Seal the retard/advance holes (C) of the intake/exhaust camshaft with tape and a wire tie. cardiagn.com 3. Seal one of the advance/retard holes (A) of the intake/exhaust camshaft with tape.
  • Page 924. Apply air to the unsealed advance/retard hole (A) to release the lock. cardiagn.com 5. Check that VTC actuator A/B moves smoothly. If VTC actuator A/B does not move smoothly, replace VTC actuator A/B. NOTE: Turn VTC actuator B by hand while applying air. 6. Remove the wire tie, the tape, and the
  • Page 931. Put the camshaft holders and the camshafts on the cylinder head, then install the camshaft holder bolts, in sequence, to 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft). 2. Tighten the camshaft holder bolts, in sequence, to the specified torque. Specified Torque: 18 N·m (1.8 kgf·m, 13 lbf·ft) 3. Zero the dial in
  • Page 948. Remove the camshaft holders. Measure the widest portion of plastigage on each journal: If the camshaft-to-holder clearance is within limits, go to step 10. If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has been replaced, replace the cylinder head. If the camsha
  • Page 9510. Measure the cam lobe (A) height. cardiagn.com Cam Lobe Height Standard (New): Intake: 33.099 mm (1.30311 in) Exhaust: 33.273 mm (1.30996 in) 3. Rocker Arm Assembly - Install 1. VTC Actuator A/B - Install
  • Page 96NOTE: If removed VTC actuator A/B, do this procedure. 1. Install VTC actuator A/B. 2. Apply new engine oil to the threads of the VTC actuator A/B mounting bolt (C), then loosely install it. 2. Camshaft - Install 1. Install the intake camshaft (A), the exhaust camshaft (C), the camshaft holders (D),
  • Page 972. Install the camshaft holder bolts, in sequence, to 5.0 N·m (0.51 kgf·m, 3.7 lbf·ft). 3. Tighten the camshaft holder bolts, in sequence, to the specified torque. Specified Torque: 18 N·m (1.8 kgf·m, 13 lbf·ft) 3. VTC Actuator A/B Mounting Bolt - Tighten cardiagn.com NOTE: If removed VTC actuator A
  • Page 982. Hold the exhaust camshaft with an open-end wrench, then tighten the VTC actuator B mounting bolt to the specified torque. Specified Torque: 115 N·m (11.7 kgf·m, 85 lbf·ft) 4. Cam Chain - Install cardiagn.com 5. Valve Clearance - Adjust 6. High Pressure Fuel Pump Base - Install 1. Apply liquid gas
  • Page 993. Apply liquid gasket to the cylinder head and the high pressure fuel pump base mating surface of the cam holder cover and to the inside edge of the threaded bolt holes. 4. Install the cam holder cover (A). cardiagn.com 5. Install the heater hose bracket (A) and the harness holder bracket (B). 6. C
  • Page 1007. Install the harness holders (A). 8. Install the ground cables (B). 9. Connect the connectors (C). cardiagn.com 7. CMP Sensor A/B - Install 8. EVAP Canister Purge Valve - Install 9. Cylinder Head Cover - Install 10.High Pressure Fuel Pump - Install 11. Intake Air Duct - Install 12.Air Cleaner - In
  • Page 10115.Ignition Timing - Inspect cardiagn.com
  • Page 102Camshaft and VTC Actuator Removal, Installation, and Inspection NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 1032 cardiagn.com Detailed information, notes, and precautions *1 These parts have inspection items. 1. Fuel Pressure - Relieve
  • Page 1042. Air Cleaner - Remove 3. Air Flow Tube A - Remove 4. High Pressure Fuel Pump - Remove 5. Vacuum Pump Holder - Remove 6. Cylinder Head Cover - Remove cardiagn.com 7. CMP Sensor A and CMP Sensor B - Remove 8. High Pressure Fuel Pump Base - Remove 9. No. 1 Piston at Top Dead Center - Set 10.Cam Chain
  • Page 105NOTE: If remove VTC actuator A/B, do step 1 and/or 2. 1. Hold the intake camshaft with an open-end wrench, then loosen the VTC actuator A mounting bolt. 2. Hold the exhaust camshaft with an open-end wrench, then cardiagn.com loosen the VTC actuator B mounting bolt. 3. Remove the camshaft holder bolt
  • Page 10613.Exhaust Camshaft - Remove cardiagn.com
  • Page 107NOTE: Carefully tip up the exhaust camshaft on the transmission side of the engine until there is enough slack in the chain to lift the chain off of the VTC actuator B's teeth. 14.Lower Exhaust Camshaft Holder - Remove 15.Intake Camshaft - Remove 16.VTC Actuator A - Remove NOTE: If remove the VTC ac
  • Page 108cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) *1 These parts have inspection items. 2
  • Page 109cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 1. VTC Actuator A - Install
  • Page 110NOTE: If removed VTC actuator A, do this procedure. 1. Install VTC actuator A. 2. Apply new engine oil to the threads of the VTC actuator A mounting bolt (B), then loosely install it. cardiagn.com 2. VTC Actuator B - Install NOTE: If removed VTC actuator B, do this procedure. 1. Install VTC actuator
  • Page 1111. Turn the crankshaft so its white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. 2. Install the intake camshaft. cardiagn.com 4. Lower Exhaust Camshaft Holder - Install 5. Exhaust Camshaft - Install 1. Slide the exhaust camshaft in at an angle to allow the c
  • Page 1126. Cam Chain Guide B, Intake Camshaft Holder, and Upper Exhaust Camshaft Holder - Install 1. Apply new engine oil to the threads of the camshaft holder bolts. cardiagn.com 2. Tighten the camshaft holder bolts, in sequence, to the specified torque. 3. If removed VTC actuator A, hold the intake camsha
  • Page 1134. If removed VTC actuator B, hold the exhaust camshaft with an open-end wrench, then tighten the VTC actuator B mounting bolt to the specified torque. 7. Cam Chain Auto-Tensioner - Install cardiagn.com 8. Camshaft Timing - Check 9. Valve Clearance - Adjust 10.High Pressure Fuel Pump Base - Install
  • Page 11416.Air Cleaner - Install 17.Fuel Leak (Low Pressure Side) - Check 1. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurizesd. Repeat this two or three times, then check for fuel leakage. 18.Fuel Leak (High Pressur
  • Page 115cardiagn.com 3. Seal one of the advance hole (A) with tape.
  • Page 1164. Apply air to the unsealed advance hole to release the lock. cardiagn.com 5. Check that VTC actuator A/B moves smoothly. If VTC actuator A/B does not move smoothly, replace VTC actuator A/B. NOTE: Turn VTC actuator B by hand while applying air. 6. Remove the wire tie, the tape, and the adhesive re
  • Page 1174. Camshaft - Inspect 1. Apply new engine oil to the threads of the camshaft holder bolts. 2. Put the rocker shaft holders, the lower exhaust camshaft holders, the intake camshaft holders, the upper exhaust camshaft holders and the camshaft on the cylinder head, then tighten the bolts, in sequence,
  • Page 1187. Install the intake camshaft holders and the upper exhaust camshaft holders, then tighten the bolts to the specified torque as shown in step 2. 8. Remove the intake camshaft holders and upper exhaust camshaft holders. Measure the widest portion of plastigage on each journal: If the camshaft-to-hol
  • Page 11910. Measure the cam lobe height. cardiagn.com Cam Lobe Height Standard (New): EXHAUST INTAKE 33.633 mm PRI (1.32413 in) 34.519 mm 34.172 mm MID (1.35901 in) (1.34535 in) 33.633 mm SEC (1.32413 in) PRI: Primary MID: Mid SEC: Secondary C/C: Cam Chain
  • Page 120Camshaft and VTC Actuator Removal, Installation, and Inspection 1. Air Cleaner - Remove 2. Intake Air Duct - Remove cardiagn.com 3. EVAP Canister Purge Valve - Remove 4. Cylinder Head Cover - Remove 5. CMP Sensor A/B - Remove 6. Harness Holder - Remove
  • Page 1211. Disconnect the ground cable (A). 2. Remove the harness holder (B). cardiagn.com 7. Camshaft Holder Cover - Remove 8. Side Cover - Remove
  • Page 1229. No. 1 Piston at Top Dead Center - Set (Crank Side) cardiagn.com 1. Turn the crankshaft so its white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. 10.No. 1 Piston at Top Dead Center - Set (Cam Side)
  • Page 1231. Set the No. 1 piston at top dead center (TDC). The ''UP'' mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuator A and VTC actuator B. The TDC marks (C) on VTC actuator B should line up with the top edge of the cam chain case (D). 11. Cam Chain Auto-Tensioner - R
  • Page 124NOTE: If remove the VTC actuator A/B, do this procedure. 1. Hold the intake camshaft with an open-end wrench, then loosen the VTC actuator A mounting bolt. 2. Hold the exhaust camshaft with an open-end wrench, then loosen the VTC actuator B mounting bolt. cardiagn.com 14.Camshaft Holder - Remove 1.
  • Page 125cardiagn.co
  • Page 1262. Remove cam chain guide B, the intake camshaft holders (A), and the upper exhaust camshaft holders (C). cardiagn.com 15.Camshaft - Remove 1. Carefully tip up the exhaust camshaft on the transmission side of the engine until there is enough slack in the chain to lift the chain off of the VTC actuat
  • Page 127cardiagn.com 16.VTC Actuator A/B - Remove NOTE: If remove the VTC actuator A/B, do this procedure. VTC Actuator Inspection 1. VTC Actuator - Inspect
  • Page 1281. Check that VTC actuator A is locked by turning VTC actuator A counterclockwise. If it is not locked, turn VTC actuator A clockwise until it stops, then recheck it. If it is still not locked, replace VTC actuator A. 2. Seal the retard holes (A) in the No. 1 camshaft journal with tape and a wire ti
  • Page 1293. Seal one of the advance hole (A) with tape. cardiagn.com 4. Apply air to the unsealed advance hole to release the lock.
  • Page 1305. Check that VTC actuator A/B moves smoothly. If VTC actuator A/B does not move smoothly, replace VTC actuator A/B. NOTE: Turn VTC actuator B by hand while applying air. 6. Remove the wire tie, the tape, and the adhesive residue from the camshaft journal. 7. VTC actuator A: Turn VTC actuator A cloc
  • Page 1313. Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth, and read the end play. If the end play is beyond the service limit, replace the cylinder head and recheck. If it is still beyond the service limit, replace the camshaft. NOTE: Do not rotate the camshaf
  • Page 132Intake: No. 2, No. 3, No. 0.060-0.099 mm (0.00236-0.00390 in) 4, No. 5 and No. 6 Journals: Exhaust: No. 3, No. 4, 0.060-0.099 mm (0.00236-0.00390 in) No. 5 and No. 6 Journals: Service Limit: 0.150 mm (0.00591 in) cardiagn.com 9. Check the total runout with the camshaft supported on V-blocks. If the
  • Page 133INTAKE EXHAUST 33.647 mm PRI (1.32468 in) 35.252 mm 34.246 mm MID (1.38787 in) (1.34827 in) 33.647 mm SEC (1.32468 in) PRI: Primary MID: Mid SEC: Secondary C/C: Cam Chain cardiagn.com 1. VTC Actuator A/B - Install NOTE: If removed VTC actuator A/B, do this procedure. 1. Install VTC actuator (A). 2.
  • Page 1341. Install the intake camshaft (A). 2. Install the lower exhaust camshaft holders (B), then slide the exhaust camshaft (C) in at an angle to allow the cam chain to slip over the teeth. cardiagn.com 3. Set the No. 1 piston at top dead center (TDC). The ''UP'' mark (A) on VTC actuator B should be at t
  • Page 135cardiagn.co
  • Page 1363. Camshaft Holder - Install 1. Apply new engine oil to the threads of the camshaft holder bolts. 2. Set the intake camshaft holders (A), the upper exhaust camshaft holders (C), and cam chain guide B in place. cardiagn.com 3. Tighten the camshaft holder bolts, in sequence, to the specified torque. S
  • Page 137NOTE: If removed VTC actuator A/B, do this procedure. 1. Hold the intake camshaft with an open-end wrench, then tighten the VTC actuator A mounting bolt to the specified torque. Specified Torque: 115 N·m (11.7 kgf·m, 85 lbf·ft) 2. Hold the exhaust camshaft with an open-end wrench, then tighten the V
  • Page 1381. Rotate the crankshaft clockwise so its white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. cardiagn.com
  • Page 1397. No. 1 Piston at Top Dead Center - Check (Cam Side) 1. Check the No. 1 piston at top dead center (TDC). The ''UP'' mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuator A and VTC actuator B. The TDC marks (C) on VTC actuator B should line up with the top edge of
  • Page 1401. Apply liquid gasket to the cylinder head mating surface of the camshaft holder cover and to the inside edge of the threaded bolt holes. 2. Install the camshaft holder cover. cardiagn.com 11. Harness Holder - Install 1. Install the harness holder (A). 2. Connect the ground cable (B). 12.CMP Sensor
  • Page 14115.Air Cleaner - Install cardiagn.com 16.Fuel Leak - Check 1. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage. 17.Ignition Timing - Inspect
  • Page 142Camshaft Timing Inspection 1. Cylinder Head Cover - Remove 2. Right Front Wheel - Remove 3. Engine Undercover - Remove 4. Camshaft Timing - Inspect 1. Turn the crankshaft to align No. 1 position at top dead center (TDC); the white mark (A) on the crankshaft pulley cardiagn.com lines up with the poin
  • Page 1431. Install the parts in the reverse order of removal. cardiagn.com
  • Page 144Camshaft Timing Inspection 1. Cylinder Head Cover - Remove 2. Right Front Wheel - Remove 3. Engine Undercover - Remove NOTE: Remove the necessary part(s). 4. Camshaft Timing - Inspect 1. Turn the crankshaft to align No. 1 position at top dead cardiagn.com center (TDC); the white mark (A) on the cran
  • Page 1453. Check the TDC marks (B) on VTC actuator A and VTC actuator B, the marks should align. The TDC marks (C) on VTC actuator B should line up with the top edge of the cam chain case (D). If the marks are not aligned, remove the cam chain and reinstall the cam chain properly. 5. All Removed Parts - Ins
  • Page 146Camshaft Timing Inspection 1. Cylinder Head Cover - Remove 2. Right Front Wheel - Remove 3. Engine Undercover - Remove 4. Camshaft Timing - Inspect 1. Turn the crankshaft to align No. 1 position at top dead center (TDC); the white mark (A) on the crankshaft pulley cardiagn.com lines up with the poin
  • Page 1475. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 148Connecting Rod and Crankshaft End Play Inspection 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch Disc, and Flywheel - Remove (M/T) 4. Drive Plate - Remove (CVT) cardiagn.com 5. Cylinder Head - Remove 6. Cam Chain Drive Sprocket - Remove 1. Remove the key (A) and the ca
  • Page 149cardiagn.co
  • Page 1509. Oil Seal Case - Remove 10.Connecting Rod End Play - Inspect 1. Measure the connecting rod end play with a feeler gauge (A) between the connecting rod (B) and the crankshaft (C). Connecting Rod End Play Standard (New): 0.15-0.35 mm (0.006-0.013 in) Service Limit: 0.45 mm (0.017 in) 2. If the conne
  • Page 1512. If the crankshaft end play is beyond the service limit, replace the thrust washers and recheck. If it is still beyond the service limit, replace the crankshaft. cardiagn.com 12.All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 152Connecting Rod and Crankshaft End Play Inspection 1. Engine - Remove 2. Transmission - Remove 3. Pressure Plate, Clutch Disc, and Flywheel - Remove 4. Cylinder Head - Remove cardiagn.com 5. Oil Pan - Remove 6. Oil Pump - Remove 7. Oil Pump Chain and Crankshaft Sprocket - Remove 8. Baffle Plate - Rem
  • Page 1532. If the connecting rod end play is beyond the service limit, install a new connecting rod, and recheck. If it is still beyond the service limit; replace the crankshaft. 10.Crankshaft End Play - Inspect cardiagn.com 1. Push the crankshaft firmly away from the dial indicator by prying, and zero the
  • Page 154Connecting Rod and Crankshaft End Play Inspection 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch Disc, and Flywheel - Remove (M/T) 4. Drive Plate - Remove (CVT) cardiagn.com 5. Cylinder Head - Remove 6. Oil Pan - Remove 7. Oil Pump - Remove 8. Oil Pump Chain - Remove 9
  • Page 155cardiagn.com 10.Connecting Rod and Crankshaft End Play - Inspect 1. Measure the connecting rod end play with a feeler gauge (A) between the connecting rod (B) and the crankshaft (C). Connecting Rod End Play Standard (New): 0.15-0.35 mm (0.006-0.013 in) Service Limit: 0.40 mm (0.015 in) 2. If the con
  • Page 1563. Push the crankshaft firmly away from the dial indicator by prying, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator by prying; the dial reading should not exceed the service limit. Crankshaft End Play Standard (New): 0.10-0.35 mm (0.00
  • Page 157Connecting Rod Bearing Replacement 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch Disc, and Flywheel - Remove (M/T) 4. Drive Plate - Remove (CVT) cardiagn.com 5. Cylinder Head - Remove 6. Oil Pan - Remove 7. Oil Strainer - Remove 8. Connecting Rod Cap and Bearing Half
  • Page 158NOTE: Keep all connecting rod caps and connecting rod bearings in order. cardiagn.com 9. Connecting Rod Bearing Clearance - Inspect 1. Clean the connecting rod journal and the bearing half with a clean shop towel. 2. Place plastigage across the rod journal. 3. Reinstall the bearing half and the conn
  • Page 159Connecting Rod Bearing-to-Journal Oil Clearance Standard (New): 0.020-0.038 mm (0.00079-0.00150 in) cardiagn.com
  • Page 1605. If the plastigage measures too wide or too narrow, remove the connecting rod cap, and the upper half of the bearing. Install a new, complete bearing with the appropriate color code, and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 6. If the pla
  • Page 161Bearing Identification 4. Use the big end bore codes and the rod journal codes to select appropriate replacement bearings from the following table. NOTE: Color code is on the edge of the bearing. When using bearing halves of different colors, it does not matter which color is used in the top or bott
  • Page 1621. Apply new engine oil to the threads of the connecting rod bolts. 2. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the connecting rod cap. 3. Install the connecting rod caps and the bolts finger-tight. 4. Rotate the cranksh
  • Page 163Connecting Rod Bearing Replacement 1. Engine - Remove 2. Transmission - Remove 3. Cylinder Head - Remove 4. Oil Pan - Remove 5. Oil Pump - Remove cardiagn.com 6. Oil Pump Chain and Crankshaft Sprocket - Remove 7. Baffle Plate - Remove 8. Connecting Rod Bearing Cap and Bearing Half - Remove 9. Connec
  • Page 1641. Clean the connecting rod journal and the bearing half with a clean shop towel. 2. Place plastigage across the rod journal. 3. Apply new engine oil to the threads and flanges of connecting rod bolts. 4. Reinstall the bearing half and the connecting rod cap, then tighten the connecting rod bolts to
  • Page 1652. Each connecting rod has a tolerance range from 0 to 0.024 mm (0.00094 in), in 0.006 mm (0.00024 in) increments, depending on the size of its big end bore. It's then stamped with a number (1, 2, 3, or 4) indicating the range. You may find any combination of numbers and bars in any engine. (Half th
  • Page 1664. Use the big end bore codes and the rod journal codes to select appropriate replacement bearings from the following table. NOTE: Color code is on the edge of the bearing. When using bearing halves of different colors, it does not matter which color is used in the top or bottom. 11. All Removed Par
  • Page 167Connecting Rod Bearing Replacement 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Cylinder Head - Remove 4. Oil Pan - Remove cardiagn.com 5. Oil Pump - Remove 6. Oil Pump Chain - Remove 7. Baffle Plate - Remove
  • Page 168cardiagn.com 8. Connecting Rod Bearing Cap and Bearing Half - Remove NOTE: Keep all connecting rod bearing caps and connecting rod bearings in order. 9. Connecting Rod Bearing Clearance - Inspect
  • Page 1691. Clean the connecting rod journal and the bearing half with a clean shop towel. 2. Place plastigage across the rod journal. 3. Reinstall the bearing half and the connecting rod bearing cap, then torque the bolts to 20 N·m (2.0 kgf·m, 15 lbf·ft) +90 °. NOTE: Apply new engine oil to the bolt threads
  • Page 1702. Each connecting rod has a tolerance range from 0 to 0.024 mm (0.00094 in), in 0.006 mm (0.00024 in) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3, or 4/l, ll, lll, or llll) indicating the range. You may find any combination of numbers and b
  • Page 17111. Connecting Rod Bolt - Inspect cardiagn.com 1. Measure the diameter of each connecting rod bolt at point A and point B. 2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter Specification: 0-0.1 mm (0-0.004 in) 3. If t
  • Page 1721. Apply new engine oil to the threads of the connecting rod bolts. 2. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the connecting rod bearing cap. 3. Install the connecting rod bearing caps and the bolts finger- tight. 4. R
  • Page 173Crankshaft and CKP Pulse Plate Removal, Installation, and Inspection Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Oil Seal Driver Attachment, 92 mm 070AD-5R00100 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch D
  • Page 1744. Drive Plate - Remove (CVT) 5. Cylinder Head - Remove 6. Cam Chain Drive Sprocket - Remove 1. Remove the key (A) and the cam chain drive sprocket (B). NOTE: Check the direction of the key. When the key is installed, install the key as same direction of the original one. cardiagn.com 7. Oil Pan - R
  • Page 17510.Connecting Rod Cap and Bearing Half - Remove cardiagn.com NOTE: Keep all connecting rod caps and connecting rod bearings in order. 11. Main Bearing Cap - Remove
  • Page 1761. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. 2. Remove the main bearing caps (A) and the main bearings cardiagn.com (B). NOTE: Check the installed position and direction of the main bearing cap
  • Page 1771. Lift the crankshaft (A) out of the engine block, being careful not to damage the CKP pulse plate (B). 2. Remove the thrust washers (C). cardiagn.com 13.CKP Pulse Plate - Remove 1. Crankshaft - Inspect Out-of-Round and Taper 1. Clean the crankshaft oil passages with pipe cleaners or a suitable bru
  • Page 178cardiagn.com 2. Check the keyway slot and the threaded holes. 3. Measure the out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round Standard (New): 0.005 mm (0.00020 in)
  • Page 1796. Check the total runout with the crankshaft supported on V-blocks. 7. Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. cardiagn.com Crankshaft Total Runout St
  • Page 1801. Apply new engine oil to the threads and flanges of CKP pulse plate mounting bolts. 2. Install the CKP pulse plate (A) on the crankshaft (B). NOTE: Be careful not to damage the CKP pulse plate. Position the mark (C) facing it out side and align the portion (D) on the CKP pulse plate and groove (E)
  • Page 1811. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine block. cardiagn.com 5. Main Bearing Cap - Install 1. Apply new engine oil to the bearing cap bolts (A) threads and flanges. 2. Install the bearing cap bolts to the main bearing ca
  • Page 182cardiagn.com 6. Bearing Cap Bolt - Tighten 1. Tighten the bearing cap bolts, in the numbered sequence shown, to the specified torque. Specified Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft) NOTE: Do not rotate the crankshaft during inspection. 2. Tighten the bearing cap bolts an additional 40 °.
  • Page 183cardiagn.com 7. Connecting Rod Bearing Clearance - Check 8. Connecting Rod Bolt - Inspect 1. Measure the diameter of each connecting rod bolt at point A and point B. 2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter S
  • Page 1841. Apply new engine oil to the threads of the connecting rod bolts. 2. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the connecting rod cap. 3. Install the connecting rod caps and the bolts finger-tight. 4. Rotate the cranksh
  • Page 1851. Remove the transmission end crankshaft oil seal. 2. Clean and dry the transmission end crankshaft oil seal housing. 3. Apply a light coat of new engine oil to the lip of the new transmission end crankshaft oil seal. 4. Use the driver handle, 15 x 135L and the oil seal driver attachment, 92 mm to
  • Page 1861. Install the cam chain drive sprocket (A) and the key (B). 15.Cylinder Head - Install cardiagn.com 16.Drive Plate - Install (CVT) 17.Pressure Plate, Clutch Disc, and Flywheel - Install (M/T) 18.Transmission - Install M/T CVT 19.Engine - Install
  • Page 187Crankshaft and CKP Pulse Plate Removal, Installation, and Inspection NOTE: Where icon is shown, click for further information. Being careful not to damage the CKP pulse plate. 1 cardiagn.com
  • Page 188cardiagn.com Detailed information, notes, and precautions *1 These parts have inspection items. 1. Engine - Remove 2. Transmission - Remove
  • Page 1893. Pressure Plate, Clutch Disc, and Flywheel - Remove 4. Transmission End Crankshaft Oil Seal - Remove 5. Cylinder Head - Remove 6. Oil Pan - Remove 7. Oil Pump - Remove 8. Oil Pump Chain and Crankshaft Sprocket - Remove cardiagn.com 9. Baffle Plate - Remove 10.Connecting Rod Bearing Cap and Bearing
  • Page 1902. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. cardiagn.com 3. Using a flat blade screwdriver, separate the lower block from the engine block in the places shown. NOTE: Keep all the bearings in o
  • Page 191NOTE: Where icon is shown, click for further information. Being careful not to damage the CKP pulse plate. 1 cardiagn.com Detailed information, notes, and precautions
  • Page 192Torque: N·m (kgf·m, lbf·ft) *1 These parts have inspection items. 1. Crankshaft Main Bearing Clearance - Check 2. CKP Pulse Plate - Install NOTE: Apply new engine oil to the threads of the CKP pulse plate mounting bolts. 3. Crankshaft - Install 1. Install the bearing halves in the engine block and t
  • Page 1931. Apply liquid gasket to the engine block mating surface of the lower block, and to the inside edge of the threaded bolt holes. 2. Put the lower block on the engine block. 3. Apply new engine oil to the threads and flange of the bearing cap bolts. 4. Torque the bearing cap bolts, in sequence, to 35
  • Page 1946. Connecting Rod Bearing Clearance - Check 7. Connecting Rod bearing Cap and Bearing Half - Install 1. Measure the diameter of each connecting rod bolt at point A and point B. 2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in
  • Page 19510. Tighten the connecting rod bolts to the specified torque. Specified Torque: 39 N·m (4.0 kgf·m, 29 lbf·ft) 11. Tighten the connecting rod bolts an additional 120 °. NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen
  • Page 196Out-of-Round and Taper 1. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. cardiagn.com 2. Check the keyway slot and the threaded holes. 3. Measure the out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal
  • Page 1976. Check the total runout with the crankshaft supported on V-blocks. 7. Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between cardiagn.com measurements on each journal must not be more than the service limit. Crankshaft Total Runout St
  • Page 198Crankshaft and CKP Pulse Plate Removal, Installation, and Inspection Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Attachment, 24 x 26 mm 07746-0010700 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch Disc, and Fl
  • Page 1994. Drive Plate - Remove (CVT) 5. Transmission End Crankshaft Oil Seal - Remove 6. Cylinder Head - Remove 7. Oil Pan - Remove 8. Oil Pump - Remove 9. Oil Pump Chain - Remove cardiagn.com 10.Baffle Plate - Remove 11. Connecting Rod Bearing Cap and Bearing Half - Remove
  • Page 200NOTE: Keep all connecting rod bearing caps and connecting rod bearings in order. cardiagn.com 12.Lower Block - Remove 1. Remove the 8 mm bolts in the sequence shown.
  • Page 2012. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. cardiagn.com 3. Using a flat blade screwdriver, separate the lower block from the engine block in the places shown.
  • Page 2024. Remove the lower block and the bearings. Keep all the bearings in order. 13.Crankshaft - Remove cardiagn.com 1. Lift the crankshaft (A) out of the engine block, being careful not to damage the CKP pulse plate (B). 14.CKP Pulse Plate - Remove
  • Page 2031. Crankshaft - Inspect cardiagn.com Out-of-Round and Taper 1. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. 2. Check the keyway slot and the threaded holes. 3. Measure the out-of-round at the middle of each rod and main journal in two places. The difference between measu
  • Page 2044. Measure the taper at the edges of each rod and the main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper Standard (New): 0.005 mm (0.00020 in) max. Service Limit: 0.010 mm (0.00039 in) Straightness 5. Place the V-blocks on a flat
  • Page 2051. Install the crankshaft end bushing when replacing the crankshaft. Using the driver handle, 15 x 135L and the bearing driver attachment, 24 x 26 mm, to drive the crankshaft end bushing squarely into the crankshaft to the specified installed height. cardiagn.com 2. Crankshaft Main Bearing Clearance
  • Page 2064. Crankshaft - Install cardiagn.com 1. Install the bearing halves in the engine block and the connecting rods. 2. Apply a coat of new engine oil to the main bearings and the connecting rod bearings. 3. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, then lower the cr
  • Page 2074. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine block. 5. Lower Block - Install 1. Apply liquid gasket to the engine block mating surface of the lower block, and to the inside edge of the threaded bolt holes. cardiagn.com 2. Pu
  • Page 2083. Apply new engine oil to the threads and flange of the bearing cap bolts. 4. Torque the bearing cap bolts, in sequence, to 35 N·m (3.6 kgf·m, 26 lbf·ft). cardiagn.com 5. Tighten the bearing cap bolts an additional 41 °. 6. Torque the 8 mm bolts, in sequence, to 24 N·m (2.4 kgf·m, 18 lbf·ft).
  • Page 2096. Connecting Rod Bearing Clearance - Check 7. Connecting Rod Bolt - Inspect 1. Measure the diameter of each connecting rod bolt at point A and point B. 2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter Specification:
  • Page 2106. Torque the connecting rod bolts to 20 N·m (2.0 kgf·m, 15 lbf·ft). 7. Tighten the connecting rod bolts an additional 90 °. NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen it back to the specified angle. 9. Baffle
  • Page 21113.Cylinder Head - Install 14.Transmission End Crankshaft Oil Seal - Install 15.Pressure Plate, Clutch Disc, and Flywheel - Install (M/T) 16.Drive Plate - Install 17.Transmission - Install M/T CVT cardiagn.com 18.Engine - Install
  • Page 212Crankshaft Main Bearing Replacement 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch Disc, and Flywheel - Remove (M/T) 4. Drive Plate - Remove (CVT) cardiagn.com 5. Cylinder Head - Remove 6. Cam Chain Drive Sprocket - Remove 1. Remove the key (A) and the cam chain drive
  • Page 2139. Oil Seal Case - Remove 10.Crankshaft - Remove 11. Crankshaft Main Bearing Clearance - Inspect 1. Clean each main journal and the bearing half with a clean shop towel. 2. Place one strip of plastigage across each main journal. 3. Apply new engine oil to the bearing cap bolts (A) threads and flange
  • Page 2147. Tighten the bearing cap bolts, in the numbered sequence shown, to the specified torque. Specified Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft) NOTE: Do not rotate the crankshaft during inspection. 8. Tighten the bearing cap bolts an additional 40 °. cardiagn.com 9. Remove the main bearing cap and the be
  • Page 21510. If the plastigage measures too wide or too narrow, remove the crankshaft, and remove the upper half of the bearing. Install a new, complete bearing with the appropriate color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. cardiagn.c
  • Page 216Main Journal Code Location 2. The main journal codes are stamped on the crankshaft. cardiagn.com Bearing Identification 3. Use the block bore codes and the main journal codes to select the appropriate replacement bearings from the following table. NOTE: Color code is on the edge of the bearing. When
  • Page 217Crankshaft Main Bearing Replacement 1. Engine - Remove 2. Transmission - Remove 3. Pressure Plate, Clutch Disc, and Flywheel - Remove 4. Transmission End Crankshaft Oil Seal - Remove 5. Cylinder Head - Remove cardiagn.com 6. Oil Pan - Remove 7. Oil Pump - Remove 8. Oil Pump Chain and Crankshaft Spro
  • Page 2181. Clean each main journal and the bearing half with a clean shop towel. 2. Place one strip of plastigage across each main journal. 3. Reinstall the main bearings and the lower block, then torque the bolts to 35 N·m (3.6 kgf·m, 26 lbf·ft). NOTE: Apply new engine oil to the bolt threads and flanges.
  • Page 2197. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below the current one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start ove
  • Page 220Bearing Identification 3. Use the block bore codes and the main journal codes to select the appropriate replacement bearings from the following table. NOTE: Color code is on the edge of the bearing. When using bearing halves of different colors, it does not matter which color is used in the top or b
  • Page 221Crankshaft Main Bearing Replacement 1. Engine - Remove 2. Transmission - Remove M/T CVT 3. Pressure Plate, Clutch Disc, and Flywheel - Remove (M/T) 4. Drive Plate - Remove (CVT) cardiagn.com 5. Transmission End Crankshaft Oil Seal - Remove 6. Cylinder Head - Remove 7. Oil Pan - Remove 8. Oil Pump -
  • Page 222cardiagn.com 11. Lower Block - Remove 12.Crankshaft Main Bearing Clearance - Inspect 1. Clean each main journal and the bearing half with a clean shop towel. 2. Place one strip of plastigage across each main journal. 3. Reinstall the main bearings and the lower block, then torque the bolts, in seque
  • Page 223Main Bearing-to-Journal Oil Clearance No. 1, No. 2, No. 4, and No. 5 Journals: Standard (New): 0.017-0.041 mm (0.00067-0.00161 in) Service Limit: 0.050 mm (0.00197 in) No. 3 Journal: Standard (New): 0.025-0.049 mm (0.00098-0.00193 in) Service Limit: 0.055 mm (0.00217 in) cardiagn.com 6. If the plast
  • Page 224Block Bore Code Location 1. Numbers, letters, or bars have been stamped on either side of the lower block end as a code for the size of each of the five main journal bores. Write down the block bore codes. If you cannot read the codes because of accumulated dirt and dust, do not scrub them with a wi
  • Page 225cardiagn.com 14.All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 226Crankshaft Pulley Removal and Installation Special Tool Required Image Description/Tool Number Holder Attachment, 50 mm, Offset 07MAB-PY3010A cardiagn.com Socket, 19 mm 07JAA-001020A or equivalent Holder Handle 07JAB-001020B 1. Right Front Wheel - Remove
  • Page 2272. Engine Undercover - Remove 3. Drive Belt - Remove 4. Crankshaft Pulley - Remove 1. Hold the crankshaft pulley with the holder handle and the holder attachment. 2. Remove the pulley bolt with a socket, 19 mm and a breaker bar. 3. Remove the crankshaft pulley. cardiagn.com 1. Crankshaft Pulley - In
  • Page 2283. Install the crankshaft pulley and the pulley bolt. 4. Hold the crankshaft pulley with the holder handle and the holder attachment, torque the pulley bolt to 70 N·m (7.1 kgf·m, 52 lbf·ft) with a torque wrench and a socket, 19mm. NOTE: Do not use an impact wrench. 5. Tighten the pulley bolt an addi
  • Page 229Crankshaft Pulley Removal and Installation Special Tool Required Image Description/Tool Number Holder Handle 07JAB-001020B cardiagn.com Holder Attachment, 50 mm, Offset 07MAB-PY3010A Socket, 19 mm 07JAA-001020A or equivalent
  • Page 230NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions 1. Right Front Wheel - Remove 2. Engine Undercover - Remove NOTE: Remove the necessary part(s). 3. Drive Belt - Remove 4. Crankshaft Pulley - Remove
  • Page 2311. Hold the crankshaft pulley with the holder handle and the holder attachment, 50 mm, offset. 2. Remove the pulley bolt with a socket, 19 mm and a breaker bar. 3. Remove the crankshaft pulley. cardiagn.com NOTE: Where icon is shown, click for further information. 1
  • Page 232Detailed information, notes, and precautions cardiagn.com 1. Crankshaft Pulley - Install 1. Remove any oil and clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D). 2. Lubricate with new engine oil as shown.
  • Page 233When a new crankshaft and/or a new pulley bolt is installed 3. Install the crankshaft pulley and the pulley bolt. 4. Hold the crankshaft pulley with the holder handle and the holder attachment, 50 mm, offset, torque the pulley bolt to 180 N·m (18.4 kgf·m, 133 lbf·ft) with a torque wrench and a socke
  • Page 2342. Drive Belt - Install cardiagn.com 3. Engine Undercover - Install 4. Right Front Wheel - Install
  • Page 235Crankshaft Pulley Removal and Installation Special Tool Required Image Description/Tool Number Holder Handle 07JAB-001020B cardiagn.com Crankshaft Pulley Holder 07AAB-RJAA100 Socket, 19 mm 07JAA-001020A or equivalent 1. Right Front Wheel - Remove
  • Page 2362. Engine Undercover - Remove 3. Drive Belt - Remove 4. Crankshaft Pulley - Remove 1. Hold the pulley with the holder handle and the crankshaft pulley holder. 2. Remove the bolt with a socket, 19 mm and a breaker bar, then remove the crankshaft pulley. cardiagn.com 1. Crankshaft Pulley - Install 1.
  • Page 237When a new crankshaft and/or a new pulley bolt is installed 2. Install the crankshaft pulley and the pulley bolt. 3. Hold the pulley with the holder handle and crankshaft pulley holder, torque the pulley bolt to 180 N·m (18.4 kgf·m, 133 lbf·ft) with a torque wrench and a socket, 19 mm, then remove t
  • Page 2382. Drive Belt - Install cardiagn.com 3. Engine Undercover - Install 4. Right Front Wheel - Install
  • Page 239Cylinder Bore Honing 1. Oil Jet - Remove 2. Cylinder Bore - Honing 1. Measure the cylinder bores. If the engine block is to be reused, hone the cylinders and remeasure the bores. Only scored or scratched cylinder bore must be honed. cardiagn.com 2. Hone the cylinder bores with honing oil and a fine
  • Page 240Cylinder Bore Honing 1. Oil Jet - Remove 2. Cylinder Bore - Honing 1. Measure the cylinder bores. If the engine block is to be reused, hone the cylinders and remeasure the bores. Only scored or scratched cylinder bore must be honed. cardiagn.com 2. Hone the cylinder bores with honing oil and a fine
  • Page 241Cylinder Head Assembly Component Location Index cardiagn.com
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  • Page 244Cylinder Head Assembly Component Location Index cardiagn.com
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  • Page 247Cylinder Head Assembly Component Location Index cardiagn.com
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  • Page 250Cylinder Head Cover Removal and Installation 1. Ignition Coil - Remove 2. Turbocharger Water Return Pipe - Remove 1. Disconnect the water bypass hose (A). 2. Remove the cylinder head cover heat insulator (B) and the turbocharger water return pipe (C). cardiagn.com 3. Breather Hose, PCV Hose, and Har
  • Page 2515. Turbocharger Bypass Control Valve Solenoid Pipe - Remove 1. Disconnect the hoses (A). 2. Remove the turbocharger bypass control valve solenoid pipe (B). cardiagn.com 6. PCV Valve - Remove 1. If necessary, remove the PCV valve. 7. Cylinder Head Cover - Remove 1. Remove the cylinder head cover (A)
  • Page 2521. Cylinder Head Cover - Install cardiagn.com
  • Page 2531. Thoroughly clean the head cover gasket (A) and the groove of the cylinder head cover (B). NOTE: Check and, if necessary, replace the head cover gasket. 2. Check the spark plug seals (C) for damage. If any seals are damaged, replace the cylinder head cover. 3. Install the head cover gasket in the
  • Page 2548. Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 7.0 N·m (0.71 kgf·m, 5.2 lbf·ft). 2. PCV Valve - Install 1. If the PCV valve is removed, install the PCV valve. cardiagn.com 3. Turbocharger Bypass Control Valve Solenoid Pipe - Install 1. Install the turbocharger
  • Page 2551. Connect the breather hose (A) and the PCV hose (B). 2. Install the harness holders (C) and the harness clamps (D). 3. Connect the connectors (E). cardiagn.com 6. Turbocharger Water Return Pipe - Install 1. Install the turbocharger water return pipe (A) and the cylinder head cover heat insulator (
  • Page 256Cylinder Head Cover Removal and Installation NOTE: Where icon is shown, click for further information. Component appearance may vary from model to model. 1 cardiagn.com
  • Page 257cardiagn.co
  • Page 2582 cardiagn.com Detailed information, notes, and precautions Replace 1. Ignition Coil - Remove
  • Page 259cardiagn.co
  • Page 2602. Connector (EVAP Canister Purge Valve) - Disconnect 3. Connector (CMP Sensor A) - Disconnect 4. Connector (VTC Oil Control Solenoid Valve B) - Disconnect 5. Harness Holder - Move 6. Dipstick - Remove 7. PCV Valve - Remove (If necessary) cardiagn.com 8. Turbocharger Bypass Control Valve Solenoid Pi
  • Page 261cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 2
  • Page 262cardiagn.com Torque: N·m (kgf·m, lbf·ft) 1. Head Cover Gasket - Install
  • Page 2631. Thoroughly clean the head cover gaskets (A) and the grooves of the cylinder head cover (B). NOTE: Check and, if necessary, replace the head cover gaskets. 2. Check the spark plug seals (C) for damage. If any seals are damaged, replace the cylinder head cover. 3. Install the head cover gaskets in
  • Page 264NOTE: When installing the break head band, do the following procedures. 1. Tighten the break head bolt until the bolt head (A) is twisted off completely. NOTE: Do not use an air tool. 2. Make sure the stopper end (B) contacts to the housing end (C) after tightening the break head bolt. 4. Water Bypa
  • Page 265Cylinder Head Cover Removal and Installation 1. Ignition Coil - Remove 2. Cylinder Head Cover External Item - Remove 1. Disconnect the connector (A). cardiagn.com 2. Remove the harness holder (B), the harness clamps (C), the connector bracket (D), and the dipstick (E).
  • Page 2663. Disconnect the PCV hose (F) and the breather hose (G). 3. PCV Valve - Remove 1. If necessary, remove the PCV valve. 4. Cylinder Head Cover - Remove 1. Cylinder Head Cover - Install cardiagn.com 1. Thoroughly clean head cover gasket A, head cover gasket B, and the grooves of the cylinder head cove
  • Page 267cardiagn.co
  • Page 2684. Apply liquid gasket to the cam chain case, the No. 5 rocker shaft holder and the high pressure fuel pump base mating areas. 5. Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cylinder head cover slightly back and forth t
  • Page 269cardiagn.com 2. Install the dipstick (C), the connector bracket (D), the harness holder (E), and the harness clamps (F). 3. Connect the connector (G). 4. Ignition Coil - Install
  • Page 270Cylinder Head Inspection for Warpage 1. Cylinder Head - Remove 2. Cylinder Head Warpage - Inspect 1. Check the cylinder head for warpage. Measure along the edges, and three ways across the center: If warpage is less than 0.08 mm (0.003 in) cylinder head resurfacing is not required. Maximum resurface
  • Page 271cardiagn.com 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 272Cylinder Head Inspection for Warpage NOTE: Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine. 1. Cylinder Head - Remove 2. Camshaft - Inspect 3. Cylinder Head Warpage - Inspect 1. Check the cylinder head for warpage. Measure along the edges, and three ways across t
  • Page 2734. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 274Cylinder Head Removal and Installation Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. NOTE: Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully whil
  • Page 2751. Disconnect the connectors (A). 2. Remove the harness clamps (B). 3. USA and Canada models: Disconnect purge tube D. 4. Remove intake air duct E. cardiagn.com 8. TWC Assembly - Remove 9. Turbocharger - Remove 10.VTC Oil Control Solenoid Valve B - Remove 11. Intake Manifold - Remove 12.High Pressur
  • Page 27615.Cylinder Head Cover - Remove cardiagn.com 16.EVAP Canister Purge Valve - Remove 17.CMP Sensor A/B - Remove 18.High Pressure Fuel Pump Base - Remove 1. Remove the ground cables (A). 2. Remove the harness holders (B).
  • Page 2773. Disconnect the heater hoses (A). 4. Remove the heater hose bracket (B) and the harness holder bracket (C). cardiagn.com 5. Remove the cam holder cover (A).
  • Page 2786. Remove the high pressure fuel pump base (A). cardiagn.com 19.Thermostat Housing - Remove 20.Cam Chain - Remove 21.Camshaft - Remove 22.Rocker Arm Assembly - Remove 23.Cylinder Head - Remove 1. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence, 1/3 turn at a time, re
  • Page 2792. Remove the cylinder head. 1. Cylinder Head - Install 1. Clean the cylinder head and engine block surfaces. 2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced. 3. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Alwa
  • Page 280When the new cylinder head bolt is installed 5. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts. 6. Torque the cylinder head bolts in sequence to 30 N·m (3.1 kgf·m, 22 lbf·ft) with a beam-type torque wrench if possible. When using a preset click-type torque wr
  • Page 2814. Cam Chain - Install 5. Valve Clearance - Adjust 6. Thermostat Housing - Install 7. High Pressure Fuel Pump Base - Install 1. Apply liquid gasket to the cylinder head mating surface of the high pressure fuel pump base and to the inside edge of the threaded bolt holes. 2. Install the high pressure
  • Page 2823. Apply liquid gasket to the cylinder head and the high pressure fuel pump base mating surface of the cam holder cover and to the inside edge of the threaded bolt holes. 4. Install the cam holder cover (A). cardiagn.com 5. Install the harness holder bracket (A) and the heater hose bracket (B). 6. C
  • Page 2837. Install the harness holders (A). 8. Install the ground cables (B). cardiagn.com 8. CMP Sensor A/B - Install 9. EVAP Canister Purge Valve - Install 10.Cylinder Head Cover - Install 11. Harness Holder Mounting Bolt - Install 12.Injector - Install
  • Page 28413.High Pressure Fuel Pump - Install 14.Intake Manifold - Install 15.VTC Oil Control Solenoid Valve B - Install 16.Turbocharger - Install 17.TWC Assembly - Install cardiagn.com 18.Intake Air Duct E - Install 1. Install intake air duct E. NOTE: Make sure the end of hose band is aligned with the mark
  • Page 28522.Intake Air Resonator - Install 23.After Installation - Check 1. After installation, check that all tubes, hoses, and connectors are installed correctly. 24.Engine Coolant - Refill 25.Fuel Leak (Low Pressure Side) - Check 1. Turn the vehicle to the ON mode, but do not start the engine. After the f
  • Page 286Cylinder Head Removal and Installation Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. NOTE: Where icon is shown, click for further information. Use fender covers to avoid damaging painted surfaces. To avoid
  • Page 287cardiagn.com Detailed information, notes, and precautions Replace 1. Fuel Pressure - Relieve 2. Engine Coolant - Drain
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  • Page 2893. 12 Volt Battery - Remove 4. Air Cleaner - Remove 5. 12 Volt Battery Base - Remove 6. TWC Assembly - Remove 7. Turbocharger - Remove 8. VTC Oil Control Solenoid Valve B - Remove cardiagn.com 9. VTC Strainer - Remove 10.EVAP Canister Purge Valve, Purge Joint, and Purge Pipe - Remove 11. Charge Air
  • Page 29017.Cylinder Head Cover - Remove 18.Cam Chain - Remove 19.Camshaft - Remove 20.Rocker Arm Assembly - Remove 21.Ground Cable - Remove cardiagn.com 22.Cylinder Head - Remove 1. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence, 1/3 turn at a time, repeat the sequence unti
  • Page 291NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft)
  • Page 292Replace cardiagn.com
  • Page 2931. Coolant Separator - Install NOTE: Install new coolant separator in the engine block whenever the engine block is replaced. 2. Dowel Pin - Install 3. Cylinder Head Gasket - Install NOTE: Clean the cylinder head and the engine block surface. 4. Cylinder Head - Install 1. Set the crankshaft to top d
  • Page 2944. If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt. When the new cylinder head bolt is installed 5. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts. 6. Torque the cylinder head bolts in sequence to 40 N·m (4.1 kgf·m, 30 lbf·f
  • Page 295When the cylinder head bolt is reused 8. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts. 9. Torque the cylinder head bolts in sequence to 40 N·m (4.1 kgf·m, 30 lbf·ft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to ti
  • Page 29610.Cylinder Head Cover - Install 11. Injector - Install 12.High Pressure Fuel Pump - Install 13.Intake Manifold - Install 14.Thermostat Housing - Install cardiagn.com 15.Vacuum Pump Holder - Install 16.Charge Air Cooler Pipe - Install NOTE: Make sure to review the hose band precautions before instal
  • Page 29723.Air Cleaner - Install 24.12 Volt Battery - Install 25.After Installation - Check 1. After installation, check that all tubes, hoses, and connectors are installed correctly. 26.Engine Coolant - Refill 27.Fuel Leak (Low Pressure Side) - Check 1. Turn the vehicle to the ON mode, but do not start the
  • Page 298Cylinder Head Removal and Installation NOTE: Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Connect the HDS to the DLC, and monitor ECT SENSOR 1. To avoid damaging the cylinder head, wait until the en
  • Page 29911. Connector (Injector) - Disconnect 12.Cylinder Head Cover - Remove 13.Cam Chain - Remove 14.Camshaft - Remove 15.Rocker Arm Assembly - Remove 16.Cylinder Head - Remove cardiagn.com 1. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence, 1/3 turn at a time, repeat the
  • Page 3001. Clean the cylinder head and the engine block surface. 2. Install new coolant separator (A) in the engine block whenever the engine block is replaced. 3. Install a new cylinder head gasket (A) and the dowel pins cardiagn.com (B) on the engine block. Always use a new cylinder head gasket.
  • Page 3014. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block. 5. Install the cylinder head on the engine block. cardiagn.com 6. Measure the diameter of each cylinder head bolt at point A and point B. 7. If either diameter
  • Page 3028. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts. 9. Torque the cylinder head bolts in sequence to 40 N·m (4.1 kgf·m, 30 lbf·ft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. I
  • Page 3038. Intake Manifold - Install 9. Thermostat Housing - Install 10.VTC Strainer - Install 11. VTC Oil Control Solenoid Valve B - Install 12.WU-TWC Assembly - Install 13.EVAP Canister Purge Valve - Install cardiagn.com 14.Air Cleaner - Install 15.12 Volt Battery Terminal - Connect 16.After Installation
  • Page 304cardiagn.co
  • Page 305Engine Assembly Torque Rod Removal and Installation NOTE: How to read the torque specifications. 1. Engine Undercover - Remove 2. Engine - Support 1. Support the engine with a transmission jack and a wood block under the oil pan. 3. Torque Rod - Remove cardiagn.com 4. Torque Rod Bracket - Remove
  • Page 306NOTE: If necessary, remove the torque rod bracket. 5. All Removed Parts - Install cardiagn.com 1. Install the parts in the reverse order of removal. NOTE: Make sure to install the torque rod with the "UP" mark (A) facing up. Do the mounts tightening procedure before tightening all of the mounts' bol
  • Page 307Engine Assembly Torque Rod Removal and Installation NOTE: Do the mounts tightening procedure before tightening all of the mounts' bolts and nuts. When installing the torque rod, make sure to install the torque rod with the "UP" mark facing up. 1 cardiagn.com
  • Page 308cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Undercover - Remove NOTE: Remove the necessary part(s).
  • Page 3092. Exhaust Pipe A - Remove cardiagn.com
  • Page 3103. Engine - Support 1. Support the engine with a transmission jack and a wood block under the oil pan. 4. Torque Rod - Remove 5. Torque Rod Bracket - Remove (if necessary) 6. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 311Engine Assembly Torque Rod Removal and Installation 1. Engine Undercover - Remove 2. Engine - Support 1. Support the engine with a transmission jack and a wood block under the oil pan. 3. Torque Rod - Remove cardiagn.com 4. Torque Rod Bracket - Remove
  • Page 312NOTE: If necessary, remove the torque rod bracket. 5. All Removed Parts - Install cardiagn.com 1. Install the parts in the reverse order of removal. NOTE: Make sure to install the torque rod with the "UP" mark (A) facing up. Do the mounts tightening procedure before tightening all of the mounts' bol
  • Page 313Engine Block Assembly Component Location Index cardiagn.com
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  • Page 316Engine Block Assembly Component Location Index cardiagn.com
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  • Page 318Engine Block Assembly Component Location Index cardiagn.com
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  • Page 320Engine Block Drain Bolt/Sealing Bolt Removal and Installation 1. Drain Bolt and Sealing Bolt - Remove 1. Remove the drain bolt (A), the sealing bolt(s) (B), and the washer(s) (C). cardiagn.com 2. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 321Engine Block Drain Bolt/Sealing Bolt Removal and Installation NOTE: How to read the torque specifications. Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine. 1. Drain Bolt and Sealing Bolt - Remove 1. Remove the drain bolt (A), the sealing bolt (B), and the washers
  • Page 322Engine Compression Inspection NOTE: A Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed. After this inspection, you must reset the PCM. Otherwise, the PCM will continue to stop the injectors from operating. 1. Engine - Warm Up 1. Start the engine. Ho
  • Page 3231. Attach a compression gauge to the spark plug hole. 2. Step on the accelerator pedal to open the throttle fully, then crank the engine with the starter motor, and measure the compression. Compression Pressure: Above 980 kPa (9.99 kgf/cm2, 142.1 psi) 3. Measure the compression on the remaining cyli
  • Page 324Engine Compression Inspection NOTE: After this inspection, you must reset the PCM. Otherwise, the PCM will continue to stop the injectors from operating. 1. Engine - Warm Up 1. Start the engine. Hold the engine speed at 3,000 rpm with no load in neutral until the radiator fan comes on, then let it i
  • Page 325Damaged or worn valves and seats Damaged cylinder head gasket Damaged or worn piston rings Damaged or worn piston and cylinder bore 5. Remove the compression gauge from the spark plug hole. 6. Ignition Coil and Spark Plug - Install 7. ALL INJECTORS STOP - Cancel 1. Select PCM reset in the PGM-FI Mod
  • Page 326Engine Compression Inspection NOTE: After this inspection, you must reset the PCM. Otherwise, the PCM will continue to stop the injectors from operating. 1. Engine - Warm Up 1. Start the engine. Hold the engine speed at 3,000 rpm with no load (M/T in neutral, CVT in P or N) until the radiator fan co
  • Page 327Damaged or worn valves and seats Damaged cylinder head gasket Damaged or worn piston rings Damaged or worn piston and cylinder bore 5. Remove the compression gauge from the spark plug hole. 6. Ignition Coil and Spark Plug - Install 7. All INJECTOR STOP - Cancel 1. Select PCM reset in the PGM-FI Mode
  • Page 328Engine Mount Tightening Procedure NOTE: How to read the torque specifications. Reinstall the mounting bolts and support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise, vibration, and severe damage to the engine mount brackets. 1. Jack - R
  • Page 329cardiagn.co
  • Page 330Engine Mount Tightening Procedure NOTE: Reinstall the mounting bolts and support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise, vibration, and severe damage to the engine mount brackets. 1. Jack - Remove 2. Engine/Transmission Mount - Ti
  • Page 331cardiagn.co
  • Page 332Engine Mount Tightening Procedure NOTE: Reinstall the mounting bolts and support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise, vibration, and severe damage to the engine mount brackets. 1. Jack - Remove 2. Engine/Transmission Mount - Ti
  • Page 333cardiagn.co
  • Page 334Engine Oil Cooler Removal and Installation NOTE: After installing all removed parts, check the engine oil level and the oil leakage. 1 cardiagn.com
  • Page 335cardiagn.co
  • Page 336Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Coolant - Drain 2. Drive Belt - Remove 3. Drive Belt Auto-Tensioner - Remove 4. A/C Compressor - Move NOTE: Do not disconnect the suction hose and the discharge cardiagn.com hose. Do not bend the suction hose and the discharge hose excessively. Hang the
  • Page 337Engine Removal and Installation Special Tool Required Image Description/Tool Number Subframe Adapter VSB02C000016* cardiagn.com Universal Lifting Eyelet 07AAK-SNAA120 *: Available through the Honda Tool and Equipment Program 888-424-6857. NOTE: Use fender covers to avoid damaging painted surfaces. T
  • Page 3381. Open the hood, and secure it with the hood support rod (A) in the wide-open position (B). 2. Fuel Pressure - Relieve cardiagn.com 3. Air Cleaner - Remove 4. 12 Volt Battery - Remove 5. PCM - Remove 6. Intake Air Duct E - Remove 7. Intake Air Duct F - Remove 8. Engine Wire Harness - Remove 1. Remo
  • Page 339cardiagn.com 2. Remove the cables (B). 3. Disconnect the connectors (C). 4. Remove the engine wire harness (D). 5. CVT: Remove the TCM harness (E). 9. Fuel Feed Hose - Disconnect
  • Page 3401. Remove the fuel feed hose (A) from the clamp (B). 2. Remove the quick-connect fitting cover (C), then disconnect the fuel feed hose.. 10.Brake Booster Vacuum Hose, Intake Air Duct G, and EVAP Canister Purge Hose - Disconnect cardiagn.com 1. Disconnect the brake booster vacuum hose (A), the EVAP c
  • Page 341cardiagn.com 11. Connector (TCM) - Disconnect (CVT)
  • Page 3421. Disconnect the connector (A). 2. Remove the ground cable (B). cardiagn.com 12.Shift Cable - Remove (CVT) 13.Slave Cylinder - Remove (M/T) 14.Change Wire Bracket - Remove (M/T) 15.Steering Joint - Disconnect NOTE: Hold the steering wheel with the steering wheel holder tool. 16.Vehicle - Lift 1. Ra
  • Page 34320.Front Brace - Remove 21.Intake Air Resonator - Remove 22.Engine Coolant - Drain 23.Engine Oil - Drain 24.Transmission Fluid - Drain M/T CVT cardiagn.com 25.Lower Radiator Pipe - Remove 1. Disconnect expansion tank outlet hose B (A) and lower radiator hose B (B). 2. Remove the lower radiator pipe
  • Page 34428.Connector (EPS Subharness) - Disconnect 29.Front Floor Brace - Remove (With Front Floor Brace) 30.Exhaust Pipe A - Remove 31.Tie-Rod End Ball Joint - Disconnect 32.Lower Stabilizer Link Ball Joint - Disconnect 33.Lower Arm Ball Joint - Disconnect cardiagn.com 34.Vehicle - Lift 1. Lower the vehicl
  • Page 345cardiagn.com 37.Vehicle - Lift 1. Raise the vehicle. 38.Torque Rod Mounting Bolt - Remove
  • Page 34639.Lower Arm Mounting Bolt - Remove cardiagn.com 40.Front Subframe - Support
  • Page 3471. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe adapter to the front subframe (B). cardiagn.com 41.Front Subframe - Remove 42.Front Driveshaft - Remo
  • Page 34847.Chain Hoist - Install cardiagn.com 1. Attach a chain hoist (A) to the universal lifting eyelet and the transmission hanger (B), then lift the engine/transmission until it is securely supported by the chain hoist.
  • Page 349cardiagn.com 48.12 Volt Battery Set Patch - Remove (if necessary)
  • Page 350cardiagn.com 49.Transmission Mount Bracket Mounting Bolt and Nut - Remove M/T
  • Page 351CVT cardiagn.com 50.Engine - Remove 1. Check that the engine/transmission is completely free of the vacuum hoses, the fuel hoses, the coolant hoses, and the electrical wiring. 2. Slowly lower the engine/transmission about 150 mm (5.91 in). Check once again that all the hoses and the electrical wirin
  • Page 352cardiagn.com 2. Engine/Transmission Assembly - Position 1. Position the engine/transmission assembly under the vehicle, and be sure that they are properly positioned. Carefully lower the vehicle, and stop with the installation position of the engine/transmission assembly. 3. Universal Lifting Eyelet
  • Page 3534. Chain Hoist - Install cardiagn.com 1. Attach a chain hoist (A) to the universal lifting eyelet and the transmission hanger (B), then lift the engine/transmission until it is securely supported by the chain hoist.
  • Page 354cardiagn.com 5. Transmission Mount Bracket Mounting Bolt and Nut - Loosely Install
  • Page 355M/T cardiagn.com CVT 6. Engine - Support 1. Lift and support the engine with a jack and a wood block under the oil pan. 7. Chain Hoist and Universal Lifting Eyelet - Remove
  • Page 3568. Side Engine Mount - Loosely Install 9. Vehicle - Lift 1. Raise the vehicle. 10.Front Driveshaft - Install 11. Front Subframe - Support 1. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tight
  • Page 35714.Torque Rod Mounting Bolt - Loosely Install cardiagn.com 15.All Engine Mount Mounting Bolt and Nut - Tighten 16.Lower Arm Ball Joint - Connect 17.Lower Stabilizer Link Ball Joint - Connect 18.Tie-Rod End Ball Joint - Connect 19.Exhaust Pipe A - Install
  • Page 35820.Front Floor Brace - Install (With Front Floor Brace) 21.Connector (EPS Subharness) - Connect 22.A/C Compressor - Install 23.Drive Belt - Install 24.Lower Radiator Pipe - Install 1. For some models: Install the washers (A). cardiagn.com 2. Install the lower radiator pipe (B). 3. Connect expansion
  • Page 35930.Water Bypass Hose and Heater Hose - Connect 1. Connect the water bypass hose (A) and the heater hoses (B). cardiagn.com 31.Change Wire Bracket - Install (M/T) 32.Slave Cylinder - Install (M/T)
  • Page 36033.Shift Cable - Install (CVT) 34.Connector (TCM) - Connect (CVT) 1. Install the ground cable (A). 2. Connect the connector (B). cardiagn.com 35.Fuel Feed Hose - Connect 1. Connect the fuel feed hose (A), then install the quick- connect fitting cover (B). 2. Install the fuel feed hose to the clamp (
  • Page 361cardiagn.com 37.Engine Wire Harness - Install 1. Install the engine wire harness (A).
  • Page 362cardiagn.com 2. CVT: Install the TCM harness (B). 3. Connect the connectors (C). 4. Install the cables (D). 5. Install the covers (E). 38.Intake Air Duct F - Install
  • Page 36339.Intake Air Duct E - Install 40.PCM - Install 41.12 Volt Battery Set Patch - Install 1. Loosen the 12 volt battery base mounting bolts. 2. Install the 12 volt battery set patch (A). 3. Tighten the 12 volt battery set patch mounting bolts and the 12 volt battery base mounting bolts, in sequence, to
  • Page 36447.Fuel Leak (Low Pressure Side) - Check 1. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurizesd. Repeat this two or three time, then check for fuel leakage. 48.Fuel Leak (High Pressure Side) - Check 49.Fluid L
  • Page 36559.Ignition Timing - Inspect 60.Transmission Gear - Check (M/T) 1. Check that the transmission shifts into all gears smoothly. 61.Shift Cable - After Install Check (CVT) 62.Wheel Alignment - Check 63.VSA Sensor Neutral Position - Memorize cardiagn.com
  • Page 366Engine Removal and Installation Special Tool Required Image Description/Tool Number Subframe Adapter VSB02C000016* cardiagn.com *: Available through the Honda Tool and Equipment Program 888-424-6857. NOTE: Use fender covers to avoid damaging painted surfaces. To avoid damaging the wiring and termina
  • Page 3672. Fuel Pressure - Relieve 3. Engine Cover - Remove 4. 12 Volt Battery - Remove 5. Air Cleaner - Remove 6. Front Grille Cover - Remove 7. PCM Assembly - Remove cardiagn.com 8. Engine Wire Harness - Remove 1. Remove the covers (A).
  • Page 368cardiagn.com 2. Disconnect the cables (B) and the connectors (C). 3. Remove the harness clamps (D) and the harness holders (E). 9. 12 Volt Battery Base - Remove 10.Charge Air Cooler Pipe - Remove
  • Page 369NOTE: Remove the necessary part(s). 11. Change Wire - Remove 12.Slave Cylinder - Remove 13.EVAP Canister Purge Hose, Vacuum Hose, and Fuel Feed Hose - Disconnect 1. Disconnect the EVAP canister purge hose (A) and the vacuum hoses (B). cardiagn.com
  • Page 370cardiagn.com 2. Remove the fuel feed hose clamps (C). 3. Remove the quick-connect fitting cover (D), then disconnect the fuel feed hose (E). 14.Steering Joint - Disconnect NOTE: Hold the steering wheel with the steering wheel holder tool.
  • Page 37115.Expansion Tank Cap - Remove 16.Vehicle - Lift 1. Raise and support the vehicle. 17.Front Wheel - Remove 18.Engine Undercover - Remove NOTE: Remove the necessary part(s). 19.Engine Coolant - Drain cardiagn.com 20.Engine Oil - Drain 21.MTF - Drain 22.Exhaust Pipe A - Remove 23.Stopper Link - Discon
  • Page 37228.Connector (Front Suspension Stroke Sensor Subharness) - Disconnect Left side Right side cardiagn.com 29.Front Suspension Stroke Sensor - Remove 30.Connector (EPS Subharness) - Disconnect 31.Front Driveshaft - Remove 32.Vehicle - Lift 1. Lower the vehicle. 33.Expansion Tank - Remove
  • Page 37334.Heater Hose - Disconnect cardiagn.com 35.Radiator - Remove 36.Vehicle - Lift 1. Raise the vehicle. 37.A/C Compressor - Move NOTE: Do not disconnect the suction hose and the discharge hose. Do not bend the suction hose and the discharge hose excessively. Hang the A/C compressor with a wire tie. 38
  • Page 37439.Front Brace - Remove cardiagn.com 40.Lower Arm Mounting Bolt - Remove 41.Front Subframe - Support
  • Page 3751. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe adapter to the front subframe (B). cardiagn.com 42.Front Subframe - Remove 43.Working Table - Positio
  • Page 376cardiagn.com 45.Transmission Mount Bracket Mounting Bolt and Nut - Remove 46.Engine - Remove 1. Check that the engine/transmission is completely free of the vacuum hoses, the fuel hoses, the coolant hoses, and the electrical wiring.
  • Page 3772. Raise the vehicle about 150 mm (5.91 in). Check once again that all the hoses and the electrical wiring are disconnected and free from the engine/transmission, then lower it all the way and support it. 3. Raise the vehicle, and remove the engine/transmission from under the vehicle. NOTE: How to r
  • Page 378cardiagn.com 4. Transmission Mount Bracket Mounting Bolt and Nut - Loosely Install 5. Vehicle - Lift 1. Raise the vehicle. 6. Front Subframe - Support
  • Page 3791. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe adapter to the front subframe (B). cardiagn.com 7. Front Subframe - Install 8. Lower Arm Mounting Bol
  • Page 38011. Vehicle - Lift cardiagn.com 1. Lower the vehicle. 12.All Engine Mount Mounting Bolt and Nut - Tighten 13.Front Driveshaft - Install 14.Lower Arm Boll Joint - Connect 15.Tie-Rod End Ball Joint - Connect 16.Stabilizer Link - Connect 17.Stopper Link - Connect 18.Exhaust Pipe A - Install 19.Charge A
  • Page 38120.Connector (EPS Subharness) - Connect 21.Front Suspension Stroke Sensor - Install 22.Connector (Front Suspension Stroke Sensor Subharness) - Connect Left side cardiagn.com Right side 23.A/C Compressor - Install 24.Vehicle - Lift 1. Lower the vehicle.
  • Page 38225.Steering Joint - Connect 26.Radiator - Install 27.Expansion Tank - Install 28.Heater Hose - Connect 29.Fuel Feed Hose, EVAP Canister Purge Hose, and Vacuum Hose - Connect cardiagn.com 1. Connect the fuel feed hose (A), then install the quick-connect fitting cover (B).
  • Page 383cardiagn.com 2. Install the fuel feed hose clamps (C). 3. Connect the EVAP canister purge hose (D) and the vacuum hoses (E). 30.Slave Cylinder - Install 31.Change Wire - Install
  • Page 38432.Charge Air Cooler Pipe - Install NOTE: Make sure to review the hose band precautions before installing the charge air cooler pipe(s). 33.12 Volt Battery Base - Install 34.Connector (Engine Wire Harness) - Connect 1. Install the harness holders (A) and the harness clamps (B). cardiagn.com
  • Page 385cardiagn.com 2. Connect the connectors (C) and the cables (D). 3. Install the covers (E). 35.PCM Assembly - Install 36.MTF - Refill
  • Page 38637.Transmission Gear - Check 1. Check that the transmission shifts into all gears smoothly. 38.Front Grille Cover - Install 39.Air Cleaner - Install 40.12 Volt Battery - Install 41.Engine Oil - Refill cardiagn.com 42.Engine Coolant - Refill 43.Fuel Leak (Low Pressure Side) - Check 1. Turn the vehicl
  • Page 38749.Front Wheel - Install 50.Vehicle - Lift 1. Lower the vehicle. 51.PCM - Reset 52.Idle Speed - Inspect 53.Ignition Timing - Inspect cardiagn.com 54.Wheel Alignment - Check 55.VSA Sensor Neutral Position - Memorize
  • Page 388Engine Removal and Installation Special Tool Required Image Description/Tool Number Subframe Adapter VSB02C000016* cardiagn.com Universal Lifting Eyelet 07AAK-SNAA120 *: Available through the Honda Tool and Equipment Program 888-424-6857. NOTE: Use fender covers to avoid damaging painted surfaces. T
  • Page 3891. Open the hood, and secure it with the hood support rod (A) in the wide-open position (B). 2. Fuel Pressure - Relieve cardiagn.com 3. Air Cleaner - Remove 4. 12 Volt Battery - Remove 5. 12 Volt Battery Set Patch - Remove 6. PCM - Remove
  • Page 3907. Engine Wire Harness - Remove 1. Remove the covers (A). cardiagn.com 2. Disconnect the cables (B) and the connectors (C). 3. Remove the engine wire harness (D).
  • Page 3914. CVT: Remove the TCM harness (E). 8. Change Wire - Disconnect (M/T) 9. Shift Cable - Disconnect (CVT) 10.Slave Cylinder - Remove (M/T) 11. Steering Joint - Disconnect NOTE: Hold the steering wheel with the steering wheel holder tool. cardiagn.com 12.Vehicle - Lift 1. Raise and support the vehicle.
  • Page 39220.Stabilizer Link - Disconnect 21.Tie-Rod End Ball Joint - Disconnect 22.Lower Arm Boll Joint - Disconnect 23.Connector (EPS) - Disconnect 24.Vehicle - Lift 1. Lower the vehicle. cardiagn.com 25.EVAP Canister Purge Hose, Vacuum Hose, and Water Bypass Hose - Disconnect 1. Disconnect the EVAP caniste
  • Page 3931. Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose (B). 27.Heater Hose - Disconnect cardiagn.com 28.Lower Radiator Pipe - Remove
  • Page 3941. Remove the lower radiator pipe (A). 2. For some models: Remove the washers (C). 3. Disconnect expansion tank outlet hose B. cardiagn.com 29.Radiator Assembly - Remove 30.A/C Compressor - Move (With A/C) NOTE: Do not disconnect the suction hose and the discharge hose. Do not bend the suction hose
  • Page 39533.Front Brace - Remove cardiagn.com 34.Lower Arm Mounting Bolt - Remove 35.Front Subframe - Support
  • Page 3961. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe adapter to the front subframe (B). cardiagn.com 36.Front Subframe - Remove 37.Front Driveshaft - Remo
  • Page 397cardiagn.com 2. Attach a chain hoist (B) to the universal lifting eyelet and the transmission hanger (C), then lift the engine/transmission until it is securely supported by the chain hoist. 42.Transmission Mount Bracket Mounting Bolt and Nut - Remove
  • Page 398M/T cardiagn.com CVT 43.Engine - Remove 1. Check that the engine/transmission is completely free of the vacuum hoses, the fuel hoses, the coolant hoses, and the electrical wiring.
  • Page 3992. Raise the vehicle about 150 mm (5.91 in). Check once again that all the hoses and the electrical wiring are disconnected and free from the engine/transmission, then lower it all the way and support it. 3. Raise the vehicle, and remove the engine/transmission from under the vehicle. 1. Torque Rod
  • Page 4002. Engine - Install 1. Position the engine/transmission assembly under the vehicle, and be sure that they are properly positioned. Carefully lower the vehicle, and stop with the installation position of the engine/transmission assembly. cardiagn.com 2. Install the universal lifting eyelet with a com
  • Page 4013. Transmission Mount Bracket Mounting Bolt and Nut - Loosely Install M/T cardiagn.com CVT 4. Engine - Support 1. Lift and support the engine with a jack and a wood block under the oil pan.
  • Page 4025. Side Engine Mount - Loosely Install 6. Vehicle - Lift 1. Raise the vehicle. 7. Front Driveshaft - Install 8. Front Subframe - Support 1. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighte
  • Page 40311. Torque Rod Mounting Bolt - Loosely Install cardiagn.com 12.All Engine Mount Mounting Bolt and Nut - Tighten 13.Vehicle - Lift 1. Raise the vehicle. 14.Front Brace - Install 15.Lower Arm Boll Joint - Connect
  • Page 40416.Tie-Rod End Ball Joint - Connect 17.Stabilizer Link - Connect 18.Exhaust Pipe A - Install 19.Connector (EPS) - Connect 20.Vehicle - Lift 1. Lower the vehicle. cardiagn.com 21.Steering Joint - Connect 22.A/C Compressor - Install (With A/C) 23.Radiator Assembly - Install 24.Lower Radiator Pipe - In
  • Page 40525.Heater Hose - Connect 26.Fuel Feed Hose - Connect cardiagn.com 1. Connect the fuel feed hose (A), then install the quick- connect fitting cover (B). 27.EVAP Canister Purge Hose, Vacuum Hose, and Water Bypass Hose - Connect
  • Page 4061. Connect the EVAP canister purge hose (A), the vacuum hoses (B), and the water bypass hose (C). 28.Slave Cylinder - Install (M/T) cardiagn.com 29.Change Wire - Connect (M/T) 30.Shift Cable - Connect (CVT) 31.Engine Wire Harness - Install 1. CVT: Install the TCM harness (A).
  • Page 407cardiagn.com 2. Install the engine wire harness (B). 3. Connect the cables (C) and the connectors (D). 4. Install the covers (E). 32.PCM - Install
  • Page 40833.Transmission Fluid - Refill M/T CVT 34.Transmission Gear - Check 1. Check that the transmission shifts into all gears smoothly. 35.12 Volt Battery Set Patch - Install 1. Loosen the 12 volt battery base mounting bolts. 2. Install the battery set patch (A). 3. Tighten the 12 volt battery set patch
  • Page 40940.Engine Undercover Lid - Install 41.Front Wheel - Install 42.Vehicle - Lift 1. Lower the vehicle. 43.Fuel Leak - Check 1. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, t
  • Page 41053.VSA Sensor Neutral Position - Memorize cardiagn.com
  • Page 411Engine Start/Stop Switch Removal and Installation 1. Driver's Dashboard Switch Panel - Remove 2. Engine Start/Stop Switch - Remove cardiagn.com 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 412Engine Start/Stop Switch Test 1. Driver's Dashboard Switch Panel - Remove 2. Engine Start/Stop Switch - Test Switch Test 1. Check the engine start/stop switch (A) according to the table. NOTE: When an LED is located between terminals, check if the LED illuminates by connecting power and ground to th
  • Page 413cardiagn.co
  • Page 414LF Antenna Test 3. Check for continuity between the terminals according to the table. There should be continuity. 4. If the continuity is not as specified, replace the engine start/stop switch. 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 415Engine Undercover Lid Removal and Installation 1. Vehicle - Lift 2. Engine Undercover Lid - Remove cardiagn.com 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 416Engine Undercover Removal and Installation NOTE: How to read the torque specifications. 1. Vehicle - Lift 2. Engine Undercover - Remove cardiagn.com
  • Page 417Without Engine Undercover Lid cardiagn.com
  • Page 418With Engine Undercover Lid cardiagn.com 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 419F-CAN Circuit Troubleshooting cardiagn.com
  • Page 420cardiagn.co
  • Page 421cardiagn.co
  • Page 422F-CAN Circuit Troubleshooting 1. F-CAN circuit resistance check: ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Jump the SCS line with the HDS, and wait more than 1 minute. ‐3. Disconnect the following connector. PCM connector No. 2 (58P) ‐4. Measure the resistance between test points 1 and 2. Tes
  • Page 423YES Repair a short in the F-CAN_H wire to the F-CAN_L wire between PCM connector No. 2 terminals No. 15 and No. 27.■ NO The F-CAN_H wire and the F-CAN_L wire are not shorted. Go to step 3. 3. Open wire check (F-CAN_H line) 1: ‐1. Check for continuity between test points 1 and 2. Test condition Vehic
  • Page 424‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector No. 2 (58P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body contro
  • Page 425‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector No. 2 (58P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body contro
  • Page 426‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector No. 2 (58P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body contro
  • Page 427‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector No. 2 (58P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body contro
  • Page 428‐2. Measure the resistance between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector No. 2 (58P): disconnected Gauge control module connector A (32P): disconnected EPS control unit connector B (6P): disconnected Body control module connector B (36P): disconnected SRS unit con
  • Page 429YES Repair a short in the F-CAN_H wire between PCM connector No. 2 terminal No. 15 and the gauge control module, the VSA modulator-control unit, the EPS control unit, the body control module, the SRS unit, the audio unit, the audio-navigation unit, the adaptive damper control unit, or the DLC.■ NO T
  • Page 430Does the HDS identify the vehicle? YES Replace the VSA modulator-control unit.■ NO (display audio type, without navigation) Reconnect the VSA modulator-control unit 46P connector with vehicle in OFF (LOCK) mode, then go to step 18. NO (with navigation) Reconnect the VSA modulator-control unit 46P co
  • Page 431‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Disconnect the following connector. Adaptive damper control unit 24P connector ‐3. Turn the vehicle to the ON mode, and read the HDS. Does the HDS identify the vehicle? YES Replace the adaptive damper control unit.■ NO Reconnect the adaptive damper co
  • Page 432F-CAN Circuit Troubleshooting cardiagn.com
  • Page 433cardiagn.co
  • Page 434cardiagn.co
  • Page 435F-CAN Circuit Troubleshooting 1. F-CAN circuit resistance check: ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Jump the SCS line with the HDS, and wait more than 1 minute. ‐3. Disconnect the following connector. PCM connector A (50P) ‐4. Measure the resistance between test points 1 and 2. Test co
  • Page 436‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected Body control module connector B (36P): disconnected EPS control
  • Page 437YES (CVT) The F-CAN_H wire is not open. Go to step 6. YES (M/T) The F-CAN_H wire is not open. Go to step 7. NO Repair an open in the F-CAN_H wire between the PCM (A37) and the SRS unit.■ 6. Open wire check (F-CAN_H line) 4: ‐1. Check for continuity between test points 1 and 2. Test condition Vehicle
  • Page 438‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected Body control module connector B (36P): disconnected EPS control
  • Page 439YES The F-CAN_L wire is not open. Go to step 11. NO Repair an open in the F-CAN_L wire between the PCM (A36) and the VSA modulator-control unit.■ 11. Open wire check (F-CAN_L line) 3: ‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P):
  • Page 440‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected Body control module connector B (36P): disconnected EPS control
  • Page 441Is there about 112-136 Ω? YES Go to step 16. NO Replace the VSA modulator-control unit.■ 16. Shorted wire check (F-CAN_H line): ‐1. Disconnect the following connectors. Gauge control module connector A (32P) VSA modulator-control unit 46P connector Body control module connector B (36P) EPS control u
  • Page 442control module, the VSA modulator-control unit, the body control module, the EPS control unit, the audio unit, the SRS unit, the TCM, or the DLC.■ NO The F-CAN_L wire is OK. Go to step 18. 18. Gauge control module check: ‐1. Reconnect all connectors. ‐2. Connect the HDS to the DLC. ‐3. Disconnect th
  • Page 443‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Disconnect the following connector. EPS control unit connector B (6P) ‐3. Turn the vehicle to the ON mode, and read the HDS. Does the HDS identify the vehicle? YES Replace the EPS control unit.■ NO (CVT) Reconnect EPS control unit connector B (6P) wit
  • Page 444F-CAN Circuit Troubleshooting cardiagn.com
  • Page 445cardiagn.co
  • Page 446cardiagn.co
  • Page 447F-CAN Circuit Troubleshooting 1. F-CAN circuit resistance check: ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Jump the SCS line with the HDS, and wait more than 1 minute. ‐3. Disconnect the following connector. PCM connector A (50P) ‐4. Measure the resistance between test points 1 and 2. Test co
  • Page 448YES Repair a short in the F-CAN_H wire to F-CAN_L wire between the PCM terminals A36 and A37.■ NO The F-CAN_H and F-CAN_L wires are not shorted. Go to step 3. 3. Open wire check (F-CAN_H line) 1: ‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connect
  • Page 449‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 450‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 451‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 452‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 453‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 454‐2. Measure the resistance between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected EPS control unit connector B (6P): disconnected Body control module connector B (36P): disconnected SRS unit connect
  • Page 455YES Repair a short in the F-CAN_H wire between the PCM (A37) and the gauge control module, the VSA modulator-control unit, the EPS control unit, the body control module, the SRS unit, the audio unit, the audio-navigation unit, the TCM, or the DLC.■ NO The F-CAN_H wire is OK. Go to step 17. 17. Short
  • Page 456Does the HDS identify the vehicle? YES Replace the VSA modulator-control unit.■ NO (with navigation) Reconnect the VSA modulator-control unit 46P connector with vehicle in OFF (LOCK) mode, then go to step 21. NO (without display audio type) Reconnect the VSA modulator-control unit 46P connector with
  • Page 457YES Replace the EPS control unit.■ NO (CVT) Reconnect EPS control unit connector B (6P) with vehicle in OFF (LOCK) mode, then go to step 23. NO (M/T) Reconnect EPS control unit connector B (6P) with vehicle in OFF (LOCK) mode, then go to step 24. 23. TCM check: ‐1. Turn the vehicle to the OFF (LOCK)
  • Page 458F-CAN Circuit Troubleshooting cardiagn.com
  • Page 459cardiagn.co
  • Page 460cardiagn.co
  • Page 461F-CAN Circuit Troubleshooting 1. F-CAN circuit resistance check: ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Jump the SCS line with the HDS, and wait more than 1 minute. ‐3. Disconnect the following connector. PCM connector A (50P) ‐4. Measure the resistance between test points 1 and 2. Test co
  • Page 462YES Repair a short in the F-CAN_H wire to F-CAN_L wire between the PCM terminals A36 and A37.■ NO The F-CAN_H and F-CAN_L wires are not shorted. Go to step 3. 3. Open wire check (F-CAN_H line) 1: ‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connect
  • Page 463‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 464Is there continuity? YES The F-CAN_H wire is not open. Go to step 8. NO Repair an open in the F-CAN_H wire between the PCM (A37) and the body control module.■ 8. Open wire check (F-CAN_L line) 1: ‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connect
  • Page 465‐1. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PCM connector A (50P): disconnected Gauge control module connector A (32P): disconnected VSA modulator-control unit 46P connector: disconnected EPS control unit connector B (6P): disconnected Body control mo
  • Page 466Is there continuity? YES The F-CAN_L wire is not open. Go to step 13. NO Repair an open in the F-CAN_L wire between the PCM (A36) and the body control module.■ 13. VSA modulator-control unit internal resistance check: ‐1. Reconnect VSA modulator-control unit 46P connector. ‐2. Measure the resistance
  • Page 467Is there continuity? YES Repair a short in the F-CAN_H wire between the PCM (A37) and the gauge control module, the VSA modulator-control unit, the EPS control unit, the body control module, the SRS unit, the audio unit, the audio-navigation unit, the adaptive damper control unit, or the DLC.■ NO Th
  • Page 468YES Replace the VSA modulator-control unit.■ OK (without navigation) Reconnect the VSA modulator-control unit 46P connector with vehicle in OFF (LOCK) mode, then go to step 18. NO (with navigation) Reconnect the VSA modulator-control unit 46P connector with vehicle in OFF (LOCK) mode, then go to ste
  • Page 469Does the HDS identify the vehicle? YES Replace the adaptive damper control unit.■ NO Reconnect the adaptive damper control unit 24P connector with vehicle in OFF (LOCK) mode, then go to step 22. 22. SRS unit check: ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Do the 12 volt battery terminal disc
  • Page 470Liquid Gasket Applying Procedure 1. Liquid Gasket - Apply 1. Apply liquid gasket as shown. NOTE: Remove all of the old liquid gasket of the mating surfaces of each part and clean. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009). Install the component within 5 minutes of applying the
  • Page 471cardiagn.co
  • Page 472cardiagn.co
  • Page 473Liquid Gasket Applying Procedure 1. Liquid Gasket - Apply 1. Apply liquid gasket as shown. NOTE: Remove all of the old liquid gasket of the mating surfaces of each part and clean. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718- 0009). Install the component within 5 minutes of applying the
  • Page 474cardiagn.co
  • Page 475cardiagn.co
  • Page 476cardiagn.co
  • Page 477Liquid Gasket Applying Procedure 1. Liquid Gasket - Apply 1. Apply liquid gasket as shown. NOTE: Remove all of the old liquid gasket of the mating surfaces of each part and clean. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718- 0009). Install the component within 5 minutes of applying the
  • Page 478cardiagn.co
  • Page 479cardiagn.co
  • Page 480cardiagn.co
  • Page 481Output Shaft (Countershaft) Speed Sensor Removal and Installation 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Undercover Plate - Remove 2. Output Shaft (Countershaft) Speed Sensor - Remove 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 482Over-Run Alternator Decoupler (OAD) Pulley Inspection Special Tool Required Image Description/Tool Number Alternator OAD Pulley Holder 07AAB-TK8A100 cardiagn.com 1. Alternator - Remove 2. OAD Pulley Seal Cap - Remove 3. Alternator OAD Pulley Holder - Insert 1. Clamp the alternator firmly in a vise.
  • Page 4834. OAD Pulley - Inspect 1. Place a beam type torque wrench (A) with a 17 mm socket wrench (B) on the alternator OAD pulley holder. 2. While holding the OAD pulley (C), rotate the alternator shaft counterclockwise. Make sure the alternator shaft is locked when applying the specified torque. Specified
  • Page 484Over-Run Alternator Decoupler (OAD) Pulley Inspection Special Tool Required Image Description/Tool Number Alternator OAD Pulley Holder 07AAB-TK8A100 cardiagn.com NOTE: Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine. 1. Alternator - Remove 2. OAD Pulley Seal Cap
  • Page 4851. Insert the alternator OAD pulley holder into the OAD pulley. 4. OAD Pulley - Inspect 1. Place a beam type torque wrench (A) with a 17 mm socket wrench (B) on the alternator OAD pulley holder. cardiagn.com 2. While holding the OAD pulley (C), rotate the alternator shaft counterclockwise. Make sure
  • Page 4865. All Removed Parts - Install 1. Install the parts in the reverse order of removal. NOTE: When installing, do not distort a new OAD pulley seal cap. Make sure to check that a new cap is installed securely. cardiagn.com
  • Page 487Over-Run Alternator Decoupler (OAD) Pulley Removal and Installation Special Tool Required Image Description/Tool Number Alternator OAD Pulley Holder 07AAB-TK8A100 cardiagn.com 1. Alternator - Remove 2. OAD Pulley Seal Cap - Remove 1. Remove the OAD pulley seal cap (A) by piercing the center of the r
  • Page 4881. Clamp the alternator firmly in a vise. 2. Insert the alternator OAD pulley holder into the OAD pulley. cardiagn.com 3. Place a 10 mm hex wrench (A) through center of the alternator OAD pulley holder (B), into hex in the end of the alternator shaft. 4. Hold the alternator OAD pulley holder with a
  • Page 489Over-Run Alternator Decoupler (OAD) Pulley Removal and Installation Special Tool Required Image Description/Tool Number Alternator OAD Pulley Holder 07AAB-TK8A100 cardiagn.com NOTE: How to read the torque specifications. Unless otherwise indicated, illustrations used in the procedure are for K20C2 e
  • Page 4903. OAD Pulley - Remove 1. Insert the alternator OAD pulley holder into the OAD pulley. cardiagn.com 2. Place a 10 mm hex wrench (A) through center of the alternator OAD pulley holder (B), into hex in the end of the alternator shaft. 3. Hold the alternator OAD pulley holder with a 17 mm wrench (C), t
  • Page 4911. Install the parts in the reverse order of removal. NOTE: When installing do not distort the OAD pulley seal cap. Make sure to check that the cap is installed securely. cardiagn.com
  • Page 492Piston, Ring, Pin, and Connecting Rod Removal and Installation 1. Crankshaft - Remove 2. Oil Jet - Remove 3. Metal or Hard Carbon - Remove 1. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructi
  • Page 4931. Using a ring expander (A), remove the old piston rings (B). 2. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. The top ring groove is 1.2 mm (0.047 in) wide. The second ring groove is 1.0 mm (0.039 in) wide. The oil
  • Page 494Oil Ring: Standard (New): 0.20-0.50 mm (0.008-0.019 in) Service Limit: 0.80 mm (0.031 in) 6. Piston Pin - Remove 1. Apply new engine oil to the snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B). NOTE: Take care not to damag
  • Page 495cardiagn.co
  • Page 4967. Piston Pin - Inspect 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 19.960-19.964 mm (0.78583-0.78598 in) Service Limit: 19.960 mm (0.78583 in) cardiagn.com 2. Zero the dial indicator (A) to the piston pin diameter. 3. Check the difference between the piston pin di
  • Page 4974. Measure the piston pin-to-connecting rod clearance. cardiagn.com Piston Pin-to-Connecting Rod Clearance Standard (New): 0.004-0.016 mm (0.00016-0.00063 in) Service Limit: 0.020 mm (0.00079 in) 1. Piston Pin - Install 1. Install a snap ring (A) only on one side.
  • Page 4982. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil. 3. Heat the piston to about 158 °F (70 °C). cardiagn.com 4. Assemble the piston (A) and the connecting rod (B). NOTE: Align the arrow (C) with the groove (D) direction on the connecting
  • Page 499cardiagn.com 2. Piston Ring - Install 1. Install the piston rings as shown. The top ring (A) has a 1RF mark, and the second ring (B) has a 2RF mark. The manufacturing marks (C) must be facing upward.
  • Page 500cardiagn.com 2. After installing a new set of rings, measure the ring-to-groove clearances: NOTE: Make sure of the mark (A) on the piston. Mark: 59B or 5PA Top Ring Clearance (59B) Standard (New): 0.065-0.090 mm (0.003 in) Service Limit: 0.130 mm (0.005 in) Top Ring Clearance (5PA) Standard (New): 0
  • Page 501cardiagn.co
  • Page 5023. Rotate the rings in their grooves to make sure they do not cardiagn.com bind. 4. Position the ring end gaps as shown. 3. Piston/Connecting Rod Assembly - Install 1. Remove the connecting rod caps. Check that the bearing is securely in place. 2. Apply new engine oil to the piston, the inside of th
  • Page 5034. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer. Push down on the ring compressor (A) to prevent the rings from expanding before entering the cylinder bore. 5. Stop after the ring compressor pops free, and check the connecting rod-to-
  • Page 504Piston, Ring, Pin, and Connecting Rod Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 505cardiagn.co
  • Page 506Detailed information, notes, and precautions *1 These parts have inspection items. 1. Crankshaft - Remove 2. Piston/Connecting Rod Assembly - Remove 1. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's
  • Page 5071. Using a ring expander (A), remove the old piston rings (B). 2. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. The top groove is 1.5 mm (0.059 in) wide. The second ring groove is 1.0 mm (0.039 in) wide. The oil ring
  • Page 5082. Remove snap rings (A) from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection. 3. Heat the piston and connecting rod assembly to about 158 °F (70 °C). cardiagn.com 4. Remove the piston pi
  • Page 509cardiagn.com Detailed information, notes, and precautions *1 These parts have inspection items. 1. Piston Pin - Install
  • Page 5101. Install a piston pin snap ring (A) only on one side. 2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil. 3. Heat the piston to about 158 °F (70 °C). cardiagn.com 4. Assemble the piston (A) and the connecting rod (B). NOTE: Align the a
  • Page 511cardiagn.com 2. Piston Ring - Install 1. Install the piston rings as shown. The top ring (A) has a 1R mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must be facing upward.
  • Page 5122. Rotate the rings in their grooves to make sure they do not bind. cardiagn.com 3. Position the ring end gaps as shown. 4. After installing a new set of rings, measure the ring-to- groove clearances. 3. Piston/Connecting Rod Assembly - Install
  • Page 5131. Remove the connecting rod bearing caps. Check that the bearing is securely in place. 2. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly. 3. Position the piston/connecting rod assemb
  • Page 514cardiagn.com 2. Measure the piston ring end-gap (B) with a feeler gauge: If the gap is too small, check to see if you have the proper rings for your engine. If the gap is too large, recheck the cylinder bore diameter against the wear limits. If the bore is beyond the service limit, the engine block
  • Page 5152. Zero the dial indicator to the piston pin diameter. cardiagn.com 3. Check the difference between the piston pin diameter and the piston pin hole diameter in the piston. Piston Pin-to-Piston Clearance Standard (New): 0.002-0.010 mm (0.00008-0.00039 in) Service Limit: 0.020 mm (0.00079 in)
  • Page 516cardiagn.com 4. Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance Standard (New): 0.004-0.016 mm (0.00016-0.00063 in) Service Limit: 0.020 mm (0.00079 in) Ring to Groove Clearance Inspection 1. Ring to Groove Clearance - Inspect 1. Measure the ring-to-groove
  • Page 517cardiagn.co
  • Page 518Piston, Ring, Pin, and Connecting Rod Removal and Installation 1. Crankshaft - Remove 2. Metal or Hard Carbon - Remove 1. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is
  • Page 5191. Using a ring expander (A), remove the old piston rings (B). 2. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. The top groove is 1.2 mm (0.047 in) wide. The second ring groove is 1.0 mm (0.039 in) wide. The oil ring
  • Page 520Second Ring Standard (New): 0.29-0.41 mm (0.012-0.016 in) Service Limit: 0.41 mm (0.016 in) Oil Ring Standard (New): 0.10-0.40 mm (0.004-0.015 in) Service Limit: 0.40 mm (0.015 in) 5. Piston Pin - Remove 1. Apply new engine oil to the piston pin snap rings (A), and turn them in the ring grooves unti
  • Page 5213. Heat the piston and connecting rod assembly to about 158 °F (70 °C). 4. Remove the piston pin. 6. Piston Pin - Inspect 1. Measure the diameter of the piston pin. cardiagn.com Piston Pin Diameter Standard (New): 19.960-19.964 mm (0.78583-0.78598 in) Service Limit: 19.957 mm (0.78571 in)
  • Page 5222. Zero the dial indicator to the piston pin diameter. 3. Check the difference between the piston pin diameter and the piston pin hole diameter in the piston. cardiagn.com Piston Pin-to-Piston Clearance Standard (New): -0.004-0.004 mm (-0.00016-0.00016 in) Service Limit: 0.007 mm (0.00028 in) 4. Mea
  • Page 5231. Piston Pin - Install 1. Install a snap ring (A) only on one side. cardiagn.com 2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil. 3. Heat the piston to about 158 °F (70 °C).
  • Page 5244. Assemble the piston (A) and the connecting rod (B). NOTE: Align the arrow (C) with the groove (D) direction on the connecting rod as shown. 5. Install the piston pin (E). 6. Install the remaining snap ring (F). 7. Turn the snap rings in the ring grooves until the end gaps are positioned at the bo
  • Page 5251. Install the top ring and the second ring as shown. The top ring (A) has a 1R mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must be facing upward. cardiagn.com
  • Page 5262. Rotate the rings in their grooves to make sure they do not bind. 3. Position the ring end gaps as shown. 4. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring Clearance Standard (New): 0.060-0.085 mm (0.003 in) cardiagn.com Service Limit: 0.11 mm (0.004 in) Secon
  • Page 5271. Remove the connecting rod bearing caps, then install the ring compressor. Check that the bearing is securely in place. 2. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly. 3. Positio
  • Page 528Pulley End Crankshaft Oil Seal Replacement - In Car Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Bearing Driver Attachment, 40 mm 07GAF-SE00200 1. Crankshaft Pulley - Remove 2. Pulley End Crankshaft Oil Seal - Remove
  • Page 5293. Pulley End Crankshaft Oil Seal - Install 1. Clean and dry the pulley end crankshaft oil seal housing. cardiagn.com 2. Apply a light coat of new engine oil to the lip of the new pulley end crankshaft oil seal. 3. Using the driver handle, 15 x 135L and the bearing driver attachment, 40 mm to drive
  • Page 5304. Measure the distance between the cam chain case surface (A) and the pulley end crankshaft oil seal (B). Oil Seal Installed Height: 10.2-10.5 mm (0.402-0.413 in) 5. Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted. 4. Crankshaft Pulley - Install cardiagn.co
  • Page 531Pulley End Crankshaft Oil Seal Replacement - In Car Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Hub Dis/Assembly Tool, 42 mm 07GAF-SD40200 NOTE: Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine. 1. Cranks
  • Page 5323. Pulley End Crankshaft Oil Seal - Install cardiagn.com 1. Clean and dry the pulley end crankshaft oil seal housing. 2. Apply a light coat of new engine oil to the lip of the new pulley end crankshaft oil seal. 3. Using the driver handle, 15 x 135L and the hub dis/assembly tool, 42 mm, drive in the
  • Page 5334. Measure the distance between the cam chain case surface (A) and the pulley end crankshaft oil seal (B). Oil Seal Installed Height (C): K20C1 Engine: 5.6-5.9 mm (0.220-0.232 in) K20C2 Engine: 5.4-6.1 mm (0.213-0.240 in) 5. Clean the excess oil off the crankshaft, and check that the pulley end cran
  • Page 534Rocker Arm and Shaft Disassembly, Reassembly, and Inspection 1. Rocker Arm Assembly - Disassemble NOTE: Identify each part as it is removed so that each item can be reinstalled in its original location. Inspect the rocker shafts and the rocker arms. If reused, the rocker arms must be installed in th
  • Page 535cardiagn.co
  • Page 5362. All Disassembled Parts - Reassembly 1. Reassemble the parts in the reverse order of disassembly. NOTE: If reused, the rocker arms must be installed in their original locations. Prior to reassembling, clean all the parts in solvent, dry them, and apply new engine oil to all contact points and the
  • Page 537Rocker Arm-to-Shaft Clearance Standard (New): 0.018-0.059 mm (0.00071-0.00232 in) Service Limit: 0.080 mm (0.00315 in) cardiagn.com 4. Repeat for all rocker arms and both shafts. If the clearance is beyond the service limit, replace the rocker shaft and all out of service limit rocker arms.
  • Page 538Rocker Arm and Shaft Disassembly, Reassembly, and Inspection NOTE: Identify each part as it is removed so that each item can be reinstalled in its original location. Inspect the rocker arm shaft and the rocker arms. If reused, the rocker arms must be installed in the their original locations. Bundle
  • Page 539cardiagn.com *1 These parts have inspection items. Intake Rocker Arm Assembly 1. Intake Rocker Shaft Cap - Remove 2. Rocker Shaft Holder - Remove
  • Page 5403. Intake Rocker Arm Assembly - Remove 4. Intake Rocker Shaft - Remove Exhaust Rocker Arm Assembly 1. Exhaust Rocker Shaft Cap - Remove 2. Exhaust Rocker Shaft - Remove 3. Thrust Washer - Remove cardiagn.com 4. Exhaust Rocker Arm Assembly - Remove 5. Lost Motion Assembly - Remove NOTE: When reassemb
  • Page 541cardiagn.com *1 These parts have inspection items. Intake Rocker Arm Assembly 1. Intake Rocker Shaft - Install 2. Intake Rocker Shaft Cap - Install
  • Page 5423. Intake Rocker Arm Assembly - Install 4. Rocker Shaft Holder - Install Exhaust Rocker Arm Assembly 1. Lost Motion Assembly - Install 2. Exhaust Rocker Arm Assembly - Install 3. Thrust Washer - Install cardiagn.com 4. Exhaust Rocker Shaft - Install 5. Exhaust Rocker Shaft Cap - Install 1. Rocker Ar
  • Page 5432. Zero the gauge (A) to the rocker shaft diameter. 3. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. cardiagn.com Rocker Arm-to-Shaft Clearance Standard (New): 0.018-0.059 mm (0.00071-0.00232 in) Service Limit: 0.080 mm (0.00315 in) 4. Repeat for all rock
  • Page 544VTEC Rocker Arms 1. Inspect the rocker arm pistons (A). Push on each piston manually. If it does not move smoothly, replace the rocker arm set. NOTE: Apply new engine oil to the rocker arm pistons when reassembling. cardiagn.com
  • Page 545Rocker Arm and Shaft Disassembly, Reassembly, and Inspection 1. Rocker Arm Assembly - Disassemble NOTE: Identify each part as it is removed so that each item can be reinstalled in its original location. Inspect the rocker arm shaft and the rocker arms. If reused, the rocker arms must be installed in
  • Page 546cardiagn.com 2. All Disassembled Parts - Reassembly 1. Reassemble the parts in the reverse order of disassembly. NOTE: When reassembling the intake rocker arm assembly, loosely tighten the rocker shaft bolt. If reused, the rocker arms must be installed in their original locations.
  • Page 547Bundle the intake rocker arms with rubber bands to keep them together as a set, and remove the bands after the intake rocker arms have been installed. Prior to reassembling, clean all the parts in solvent, dry them, and apply new engine oil to all contact points, the bearing surface, and the lost mo
  • Page 5483. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance Standard (New): 0.018-0.059 mm (0.00071-0.00232 in) Service Limit: 0.080 mm (0.00315 in) cardiagn.com 4. Repeat for all rocker arms and both shafts. If the clearance is beyond
  • Page 549Rocker Arm Assembly Removal and Installation 1. Air Cleaner - Remove 2. 12 Volt Battery - Remove 3. Intake Air Duct E - Remove 4. Camshaft - Remove 5. Sealing Bolt - Remove cardiagn.com 1. Remove the sealing bolt (A) and the washer (B). NOTE: When the new washer is installed, apply new engine oil to
  • Page 5501. Remove the rocker shaft bolts (A). cardiagn.com 2. Remove the intake rocker shaft (A), the exhaust rocker shaft (B), the intake rocker arm assemblies (C), the exhaust rocker arm assemblies (D), and the thrust washers (E). 7. All Removed Parts - Install 1. Install the parts in the reverse order of
  • Page 551Rocker Arm Assembly Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions
  • Page 552Replace cardiagn.com
  • Page 5531. Fuel Pressure - Relieve 2. Engine Coolant - Drain 3. 12 Volt Battery - Remove 4. Air Cleaner - Remove 5. 12 Volt Battery Base - Remove 6. PCM Assembly - Remove cardiagn.com 7. EVAP Canister Purge Valve, Purge Joint, and Purge Pipe - Remove 8. Charge Air Cooler Pipe - Remove NOTE: Remove the neces
  • Page 55415.Exhaust Rocker Arm Assembly - Remove NOTE: Bundle the exhaust rocker arms with rubber band to keep them together as a set. 16.Lost Motion Assembly - Remove NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 555cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Apply new engine oil on both sides. 1. Intake Rocker Arm Assembly - Reassemble NOTE: If the intake rocker arm assembly is disassembled,
  • Page 556reassemble the intake rocker arm assembly. cardiagn.com
  • Page 5572. Lost Motion Assembly - Install NOTE: Apply new engine oil to the lost motion assembly. 3. Exhaust Rocker Arm Assembly - Install 4. Exhaust Rocker Shaft - Install NOTE: After install the exhaust rocker shaft, remove the rubber band as it was installed when removing the exhaust rocker shaft assembl
  • Page 55810.Valve Clearance - Adjust cardiagn.com
  • Page 55911. High Pressure Fuel Pump Base - Install 12.CMP Sensor A and CMP Sensor B - Install 13.Thermostat Housing - Install 14.Vacuum Pump Holder - Install 15.High Pressure Fuel Pump - Install cardiagn.com 16.Cylinder Head Cover - Install 17.Charge Air Cooler Pipe - Install NOTE: Make sure to review the h
  • Page 560cardiagn.co
  • Page 56124.Fuel Leak (Low Pressure Side) - Check 1. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurizesd. Repeat this two or three times, then check for fuel leakage. 25.Fuel Leak (High Pressure Side) - Check 26.Igniti
  • Page 562Rocker Arm Assembly Removal and Installation 1. Engine Coolant - Drain 2. 12 Volt Battery - Remove 3. Intake Air Duct - Remove 4. Air Cleaner - Remove cardiagn.com 5. EVAP Canister Purge Valve - Remove 6. Thermostat Housing - Remove 7. Camshaft - Remove 8. Rocker Arm Assembly - Remove
  • Page 5631. Remove the sealing bolt (A) and the washer (B). 2. Remove the intake rocker arm assembly (A). cardiagn.com 3. Remove the lost motions (B).
  • Page 5644. Remove the rocker shaft bolt (A) and the exhaust rocker shaft cap (B). 5. Remove the exhaust rocker shaft (A), the exhaust rocker arm assembly (B), and the thrust washers (C). cardiagn.com 1. Intake Rocker Arm Assembly - Reassemble NOTE: If the intake rocker arm assembly is disassembled, reassemb
  • Page 5651. Install the exhaust rocker arm assembly (A), the thrust washers (B), and the exhaust rocker shaft (C). 2. Install the exhaust rocker shaft cap (A) and the rocker shaft bolt (B). cardiagn.com 3. Install the lost motions (A). NOTE: Apply new engine oil to the lost motion assembly. 4. Apply liquid g
  • Page 5665. Install the intake rocker arm assembly (B). 6. Apply new engine oil to a new washer (A). 7. Install the sealing bolt (B) with the new washer. cardiagn.com 3. No. 1 Piston at Top Dead Center - Set (Crank Side) 1. Turn the crankshaft so its white mark (A) on the crankshaft pulley lines up with the
  • Page 5671. Install the intake camshaft (A). 2. Install the lower exhaust camshaft holders (B), then slide the exhaust camshaft (C) in at an angle to allow the cam chain to slip over the teeth. cardiagn.com 3. Set the No. 1 piston at top dead center (TDC). The ''UP'' mark (A) on VTC actuator B should be at t
  • Page 568cardiagn.co
  • Page 5695. Camshaft Holder - Install 1. Apply new engine oil to the threads of the camshaft holder bolts. 2. Set the intake camshaft holders (A), the upper exhaust camshaft holders (C), and cam chain guide B in place. cardiagn.com 3. Tighten the camshaft holder bolts, in sequence, to the specified torque. S
  • Page 5701. If the intake rocker arm assembly is disassembled, tighten the rocker shaft bolt (A). 7. Cam Chain Auto-Tensioner - Install cardiagn.com 8. No. 1 Piston at Top Dead Center - Set (Crank Side) 1. Rotate the crankshaft clockwise so its white mark (A) on the crankshaft pulley lines up with the pointe
  • Page 5711. Check the No. 1 piston at top dead center (TDC). The ''UP'' mark (A) on VTC actuator B should be at the top. Align the TDC marks (B) on VTC actuator A and VTC actuator B. The TDC marks (C) on VTC actuator B should line up with the top edge of the cam chain case (D). 10.Valve Clearance - Adjust 11
  • Page 5721. Apply liquid gasket to the cylinder head mating surface of the camshaft holder cover and to the inside edge of the threaded bolt holes. 2. Install the camshaft holder cover. cardiagn.com 13.Harness Holder - Install 1. Install the harness holder (A). 2. Connect the ground cable (B). 14.CMP Sensor
  • Page 57317.Cylinder Head Cover - Install 18.EVAP Canister Purge Valve - Install 19.Intake Air Duct - Install cardiagn.com 20.Air Cleaner - Install 21.12 Volt Battery - Install 22.Engine Coolant - Refill 23.Ignition Timing - Inspect
  • Page 574Rocker Arm Oil Control Valve Removal and Installation 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Cover - Remove 2. Expansion Tank - Move 3. Rocker Arm Oil Control Valve Assembly - Remove 4. All Removed Parts - Install
  • Page 575cardiagn.co
  • Page 5761. Install the parts in the reverse order of removal. cardiagn.com
  • Page 577Rocker Arm Oil Control Valve Removal and Installation 1 With Rocker Arm Oil Pressure Switch Torque: N·m (kgf·m, lbf·ft) cardiagn.com Replace 2 Without Rocker Arm Oil Pressure Switch
  • Page 578cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Expansion Tank - Move NOTE: Do not disconnect the water bypass hoses. Do not bend the water bypass hoses excessively. 2. Rocker Arm Oil Control Valve Assembly - Remove 3. Engine Oil Pressure Switch - Remove (if necessary) 4. Rocker Arm Oil Pressure
  • Page 579Rocker Arm Oil Pressure Switch Removal and Installation 1. Rocker Arm Oil Pressure Switch - Remove 1. Disconnect the connector (A). 2. Remove the rocker arm oil pressure switch (B) with the O-ring (C). 2. All Removed Parts - Install cardiagn.com 1. Install the parts in the reverse order of removal w
  • Page 580Rocker Arm Oil Pressure Sensor Removal and Installation 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Cover - Remove 2. Expansion Tank - Move 3. Rocker Arm Oil Pressure Sensor - Remove 4. All Removed Parts - Install
  • Page 581cardiagn.co
  • Page 5821. Install the parts in the reverse order of removal. cardiagn.com
  • Page 583Rocker Arm Oil Pressure Switch Removal and Installation 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Cover - Remove 2. Expansion Tank - Move 3. Rocker Arm Oil Pressure Switch - Remove 4. All Removed Parts - Install
  • Page 584cardiagn.co
  • Page 5851. Install the parts in the reverse order of removal. cardiagn.com
  • Page 586Secondary HO2S Removal and Installation Special Tool Required Image Description/Tool Number O2 Sensor Wrench Snap-on S6176 or equivalent, commercially available cardiagn.com NOTE: Where icon is shown, click for further information. 1
  • Page 587Detailed information, notes and precautions cardiagn.com Torque: N·m (kgf·m, lbf·ft) Secondary HO2S 1. Secondary HO2S - Remove
  • Page 5881. Using a commercially available O2 sensor wrench, remove secondary HO2S. cardiagn.com 2. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 589Secondary HO2S Removal and Installation Special Tool Required Image Description/Tool Number O2 Sensor Socket Wrench Snap-on SWR2 or Snap-on YA8875, commercially available cardiagn.com NOTE: Where icon is shown, click for further information. 1
  • Page 590cardiagn.com Detailed information, notes and precautions Torque: N·m (kgf·m, lbf·ft) 1. Connector (Secondary HO2S) - Disconnect 2. Secondary HO2S - Remove 1. Using a commercially available O2 sensor socket wrench, remove secondary HO2S.
  • Page 5913. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 592Secondary HO2S Removal and Installation Special Tool Required Image Description/Tool Number O2 Sensor Socket Wrench Snap-on SWR2 or Snap-on YA8875, commercially available cardiagn.com NOTE: Where icon is shown, click for further information. 1
  • Page 593cardiagn.com Detailed information, notes and precautions Torque: N·m (kgf·m, lbf·ft) 1. Intake Air Duct - Remove 2. Connector (Secondary HO2S) - Disconnect 3. Secondary HO2S - Remove
  • Page 5941. Using a commercially available O2 sensor socket wrench, remove secondary HO2S. cardiagn.com 4. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 595Side Engine Mount Removal and Installation NOTE: How to read the torque specifications. Unless otherwise indicated, illustrations used in the procedure are for the model with the dynamic damper and the bracket. 1. Engine Undercover Plate - Remove 2. Engine - Support 1. Lift and support the engine wi
  • Page 5961. Remove the ground cable (A). 2. Remove the side engine mount bracket (B). 3. Remove the side engine mount (C). cardiagn.com 6. All Removed Parts - Install 1. Install the parts in the reverse order of removal. NOTE: Do the mounts tightening procedure before tightening all of the mounts' bolts and
  • Page 597Side Engine Mount Removal and Installation NOTE: Do the mounts tightening procedure before tightening all of the mounts' bolts and nuts. 1 cardiagn.com
  • Page 598cardiagn.co
  • Page 599Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Undercover Plate - Remove 2. Engine - Support 1. Lift and support the engine with a jack and a wood block under the oil pan. 3. Expansion Tank - Move NOTE: Do not disconnect the water bypass hoses. 4. Ground Cable - Remove cardiagn.com 5. Side Engine Mou
  • Page 600Side Engine Mount Removal and Installation 1. Engine Undercover Plate - Remove 2. Engine - Support 1. Lift and support the engine with a jack and a wood block under the oil pan. 3. Expansion Tank - Move NOTE: Do not disconnect the water bypass hoses. cardiagn.com 4. Side Engine Mount - Remove 1. Rem
  • Page 601Valve Clearance Adjustment Special Tool Required Image Description/Tool Number Adjuster 07MAA-PR70110 cardiagn.com Locknut Wrench 07MAA-PR70120 NOTE: Connect the HDS to the DLC and monitor ECT SENSOR 1 with the HDS. Adjust the valve clearance only when the engine coolant temperature is less than 100
  • Page 6021. Turn the crankshaft to align No. 1 position at top dead center (TDC); the white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. 2. Set the No. 1 piston at top dead center (TDC). The "UP" cardiagn.com mark (A) on VTC actuator A should be at the top and align
  • Page 6034. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and slide it back and forth; you should feel a slight amount of drag. 5. If you feel too much or too little drag, loosen the locknut cardiagn.com with the locknut wrench, and turn the
  • Page 6047. Rotate the crankshaft clockwise. The "3" mark (A) on VTC actuator A should be at the top. 8. Check and, if necessary, adjust the valve clearance on the No. 3 cylinder. 9. Rotate the crankshaft clockwise. The "4" mark (A) on VTC cardiagn.com actuator A should be at the top. 10. Check and, if neces
  • Page 6053. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 606Valve Clearance Adjustment Special Tool Required Image Description/Tool Number Adjuster 07MAA-PR70110 cardiagn.com Locknut Wrench 07MAA-PR70120 NOTE: Connect the HDS to the DLC and monitor ECT SENSOR 1 with the HDS. Adjust the valve clearance only when the engine coolant temperature is less than 100
  • Page 607NOTE: Remove the necessary part(s). 4. Valve Clearance - Adjust 1. Turn the crankshaft to align No. 1 position at top dead center (TDC); the white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. cardiagn.com 2. Set the No. 1 piston at top dead center (TDC). The
  • Page 6084. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and slide it back and forth; you should feel a slight amount of drag. cardiagn.com 5. If you feel too much or too little drag, loosen the locknut with the locknut wrench and the adjust
  • Page 6097. Rotate the crankshaft clockwise. The ''3'' mark (A) on VTC actuator B should be at the top. 8. Check and, if necessary, adjust the valve clearance on the No. 3 cylinder. 9. Rotate the crankshaft clockwise. The ''4'' mark (A) on VTC actuator B should be at the top. cardiagn.com 10. Check and, if n
  • Page 61012. Check and, if necessary, adjust the valve clearance on the No. 2 cylinder. 5. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 611Valve Clearance Adjustment Special Tool Required Image Description/Tool Number Adjuster 07MAA-PR70110 cardiagn.com Locknut Wrench 07MAA-PR70120 NOTE: Connect the HDS to the DLC and monitor ECT SENSOR 1 with the HDS. Adjust the valve clearance only when the engine coolant temperature is less than 100
  • Page 6124. Valve Clearance - Adjust 1. Turn the crankshaft to align No. 1 position at top dead center (TDC); the white mark (A) on the crankshaft pulley lines up with the pointer (B) on the cam chain case. cardiagn.com 2. Set the No. 1 piston at top dead center (TDC). The "UP" mark (A) on VTC actuator B sho
  • Page 6134. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and cardiagn.com slide it back and forth; you should feel a slight amount of drag.
  • Page 6145. If you feel too much or too little drag, loosen the locknut with the locknut wrench and the adjuster, and turn the adjusting screw until the drag on the feeler gauge is correct. 6. Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary. Specifie
  • Page 6159. Rotate the crankshaft clockwise. The ''4'' mark (A) on VTC actuator B should be at the top. 10. Check and, if necessary, adjust the valve clearance on the No. 4 cylinder. cardiagn.com 11. Rotate the crankshaft clockwise. The ''2'' mark (A) on VTC actuator B should be at the top. 12. Check and, if
  • Page 616Valve Guide Replacement Special Tool Required Image Description/Tool Number Valve Guide Driver, 5.35 x 9.7 mm 07742-0010100 cardiagn.com Valve Guide Reamer, 5.5 mm 07HAH-PJ7A100 Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves con
  • Page 6173. Valve Guide - Remove 1. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the valve guide driver, 5.35 x 9.7 mm and a conventional hammer. 2. Select the proper replac
  • Page 6184. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.08 in) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Wear s
  • Page 619cardiagn.com 2. Apply a thin coat of new engine oil to the outside of the new valve guide. 3. Install the guide from the camshaft side of the head; use the valve guide driver, 5.35 x 9.7 to drive the guide into the specified installed height (A) of the guide (B). If you have all 16 valve guides to d
  • Page 6204. Coat both the valve guide reamer, 5.5 mm and the valve guide with cutting oil. 5. Rotate the valve guide reamer clockwise the full length of the valve guide bore. 6. Continue to rotate the reamer clockwise while drawing it from the bore. 7. Thoroughly wash the guide in detergent and water to remo
  • Page 621Valve Guide Replacement Special Tool Required Image Description/Tool Number Valve Guide Driver, 5.35 x 9.7 mm 07742-0010100 cardiagn.com Valve Guide Reamer, 5.5 mm 07HAH-PJ7A100 Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves con
  • Page 6223. Valve Guide - Remove 1. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the valve guide driver, 5.35 x 9.7 mm and a conventional hammer. 2. Select the proper replac
  • Page 623cardiagn.com 4. Valve Guide - Install 1. Take out the new valve guide(s) from the freezer, one at a time, as you need them. 2. Apply a thin coat of new engine oil to the outside of the new valve guide. 3. Install the guide from the camshaft side of the head; use the valve guide driver to drive the g
  • Page 6244. Coat both the valve guide reamer, 5.5 mm and the valve guide with cutting oil. 5. Rotate the valve guide reamer clockwise the full length of the valve guide bore. 6. Continue to rotate the reamer clockwise while drawing it from the bore. 7. Thoroughly wash the guide in detergent and water to remo
  • Page 625Valve Guide Replacement Special Tool Required Image Description/Tool Number Valve Guide Driver, 5.35 x 9.7 mm 07742-0010100 cardiagn.com Valve Guide Reamer, 5.5 mm 07HAH-PJ7A100 1. Valve Seal and Valve Spring Seat - Remove 2. Valve Stem-to-Guide Clearance - Inspect 3. Valve Guide - Remove
  • Page 6261. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the valve guide driver, 5.35 x 9.7 mm and a conventional hammer. 2. Select the proper replacement guides, and chill
  • Page 627cardiagn.com 4. Valve Guide - Install 1. Take out the new valve guide(s) from the freezer, one at a time, as you need them. 2. Apply a thin coat of new engine oil to the outside of the new valve guide. 3. Install the guide from the camshaft side of the head; use the valve guide driver to drive the g
  • Page 6284. Coat both the valve guide reamer, 5.5 mm and the valve guide with cutting oil. 5. Rotate the valve guide reamer clockwise the full length of the valve guide bore. 6. Continue to rotate the reamer clockwise while drawing it from the bore. 7. Thoroughly wash the guide in detergent and water to remo
  • Page 629Valve Inspection Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. 1. Valve - Remove 2. Valve - Inspect 1. Measure the valve in these areas. Intake Valve Dimensions cardiagn.com A Standard (New): 27.90-28.10 m
  • Page 630Valve Inspection Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. 1. Valve - Remove 2. Valve - Inspect 1. Measure the valve in these areas. Intake Valve Dimensions cardiagn.com A Standard (New): 34.85-35.15 m
  • Page 631Valve Inspection 1. Valve - Remove 2. Valve - Inspect 1. Measure the valve in these areas. Intake Valve Dimensions A Standard (New): 34.85-35.15 mm (1.3720-1.3839 in) B Standard (New): 116.95-117.55 mm (4.6043-4.6279 in) C Standard (New): 5.475-5.490 mm (0.21555-0.21614 in) C Service Limit: 5.445 mm
  • Page 632Valve Seat Reconditioning Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. 1. Valve Seat - Reconditioning 1. Inspect valve stem-to-guide clearance. If the valve guides are worn, replace them before cutting th
  • Page 633Valve Seat Width (Intake/Exhaust) Standard (New): 1.25-1.55 mm (0.0492-0.0610 in) Service Limit: 2.00 mm (0.0787 in) 6. After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it
  • Page 634Valve Seat Reconditioning Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. 1. Valve Seat - Reconditioning 1. Inspect valve stem-to-guide clearance. If the valve guides are worn, replace them before cutting th
  • Page 635Service Limit: 1.90 mm (0.0748 in) Exhaust: Standard (New): 1.45-1.75 mm (0.0571-0.0689 in) Service Limit: 2.22 mm (0.0874 in) 6. After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, the
  • Page 636cardiagn.co
  • Page 637Valve Seat Reconditioning 1. Valve Seat - Reconditioning 1. Inspect valve stem-to-guide clearance. If the valve guides are worn, replace them before cutting the valve seats. 2. Renew the valve seats in the cylinder head using a valve seat cutter. 3. Carefully cut a 45 ° seat, removing only enough ma
  • Page 6386. After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times. 7. The actual valve seating surface (B), as shown by the blue comp
  • Page 639Valve Stem-to-Guide Clearance Inspection Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. 1. Valve - Remove 2. Valve - Inspect 3. Valve Stem To Guide Clearance - Inspect cardiagn.com 1. Subtract the O.D. of t
  • Page 6401. Install the parts in the reverse order of removal. cardiagn.com
  • Page 641Valve Stem-to-Guide Clearance Inspection Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium. 1. Valve - Remove 2. Valve - Inspect 3. Valve Stem To Guide Clearance - Inspect cardiagn.com 1. Subtract the O.D. of t
  • Page 642Valve Stem-to-Guide Clearance Inspection 1. Valve - Remove 2. Valve - Inspect 3. Valve Stem to Guide Clearance - Inspect 1. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in th
  • Page 643Valve, Spring, and Valve Seal Removal and Installation Special Tool Required Image Description/Tool Number Valve Spring Compressor Attachment 070AE-5K0A100 cardiagn.com Stem Seal Driver 07PAD-0010000 Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as
  • Page 6441. Using an appropriate-sized socket (A) and a plastic mallet (B), lightly tap the spring retainer to loosen the valve cotters. 2. Install the valve spring compressor attachment and the cardiagn.com valve spring compressor. 3. Compress the valve spring and remove the valve cotters. 4. Remove the val
  • Page 6451. Install the valve guide seal remover (A). cardiagn.com 2. Remove the valve seal. 4. Valve Spring Seat - Remove
  • Page 6461. Valve Spring Seat and Valve Seal - Install cardiagn.com 1. Coat the valve stems with new engine oil. 2. Install the valves in the valve guides. 3. Check that the valves move up and down smoothly, then remove the valves.
  • Page 6474. Install the valve spring seat (A). 5. Install the new valve seal (A) using the 5.5 mm side of the cardiagn.com stem seal driver. NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white or silver spring (F), they are not interchangeable. 2. Valve and Valv
  • Page 6481. Install the valve, the valve spring, and the spring retainer. Place the end of the valve spring with the closely wound coils toward the cylinder head. 2. Install the valve spring compressor attachment and the valve spring compressor. 3. Compress the valve spring and install the valve cotters. 4.
  • Page 649Valve, Spring, and Valve Seal Removal and Installation Special Tool Required Image Description/Tool Number Valve Spring Compressor Attachment 070AE-5K0A100 cardiagn.com Stem Seal Driver 07PAD-0010000 Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as
  • Page 650cardiagn.com Detailed information, notes, and precautions Replace 1. Cylinder Head - Remove 2. Valve and Valve Spring - Remove
  • Page 6511. Using an appropriate-sized socket (A) and a plastic mallet (B), lightly tap the spring retainer to loosen the valve cotters. 2. Install the valve spring compressor and the valve spring compressor attachment. cardiagn.com 3. Compress the valve spring and remove the valve cotters. 4. Remove the val
  • Page 6521. Install the valve guide seal remover (A). cardiagn.com 2. Remove the valve seal. 4. Valve Spring Seat - Remove NOTE: Where icon is shown, click for further information. 1
  • Page 653cardiagn.com Detailed information, notes, and precautions Replace 1. Valve Spring Seat - Install 2. Valve Seal - Install
  • Page 6541. Install the valve seals (A) using the 5.5 mm side of the stem seal driver. NOTE: The exhaust valve seal (B) has a black spring (C), and the intake valve seal (D) has a white or silver spring (E), they are not interchangeable. cardiagn.com 3. Valve and Valve Spring - Install 1. Coat the valve stem
  • Page 6554. Install the valve spring and the spring retainer. Place the end of the valve spring with the closely wound coils toward the cylinder head. 5. Install the valve spring compressor and the valve spring compressor attachment. 6. Compress the valve spring and install the valve cotters. 7. Remove the v
  • Page 656Valve, Spring, and Valve Seal Removal and Installation Special Tool Required Image Description/Tool Number Valve Spring Compressor Attachment 070AE-5K0A100 cardiagn.com Stem Seal Driver 07PAD-0010000 NOTE: Identify the valves and the valve springs as they are removed so that each item can be reinsta
  • Page 6571. Using an appropriate-sized socket (A) and a plastic mallet (B), lightly tap the spring retainer to loosen the valve cotters. 2. Install the valve spring compressor and the valve spring compressor attachment. cardiagn.com 3. Compress the valve spring and remove the valve cotters. 4. Remove the val
  • Page 6581. Install the valve guide seal remover (A). cardiagn.com 2. Remove the valve seal. 4. Valve Spring Seat - Remove
  • Page 6591. Valve Spring Seat - Install cardiagn.com 2. Valve Seal - Install
  • Page 6601. Install the new valve seals (A) using the 5.5 mm side of the stem seal driver. NOTE: The exhaust valve seal (B) has a black spring (C), and the intake valve seal (D) has a white or silver spring (E), they are not interchangeable. cardiagn.com 3. Valve and Valve Spring - Install 1. Coat the valve
  • Page 6614. Install the valve spring and the spring retainer. Place the end of the valve spring with the closely wound coils toward the cylinder head. 5. Install the valve spring compressor and the valve spring compressor attachment. 6. Compress the valve spring and install the valve cotters. 7. Remove the v
  • Page 662VTC Oil Control Solenoid Valve Removal, Installation, and Test NOTE: Where icon is shown, click for further information. 1 Intake Side (VTC Oil Control Solenoid Valve A) cardiagn.com Detailed information, notes and precautions Torque: N·m (kgf·m, lbf·ft) Replace 2 Exhaust Side (VTC Oil Control Solen
  • Page 663cardiagn.com Detailed information, notes and precautions Torque: N·m (kgf·m, lbf·ft) Replace Intake side (VTC Oil Control Solenoid Valve A) 1. Engine Cover - Remove 2. Expansion Tank - Move 3. Ground Cable Terminal - Disconnect 4. VTC Oil Control Solenoid Valve A - Remove Note for installation Coat
  • Page 6645. All Removed Parts - Install 1. Install the parts in the reverse order of removal. Exhaust side (VTC Oil Control Solenoid Valve B) 1. Engine Cover - Remove 2. Turbocharger Inlet Joint Pipe - Remove 3. VTC Oil Control Solenoid Valve B - Remove Note for installation cardiagn.com Coat the O-ring with
  • Page 6651. Connect VTC oil control solenoid valve 2P (male terminals) (A) connector No. 1 to the battery positive terminal with a jumper wire. Connect VTC oil control solenoid valve 2P (male terminals) (A) connector No. 2 to the battery negative terminal with a jumper wire. 2. Measure the clearance of the v
  • Page 666VTC Oil Control Solenoid Valve Removal, Installation, and Test Intake Side (VTC Oil Control Solenoid Valve A) 1. VTC Oil Control Solenoid Valve A - Remove 1. Disconnect the connector (B). 2. Remove VTC oil control solenoid valve A with the O-ring (C). 2. All Removed Parts - Install cardiagn.com 1. I
  • Page 6671. Disconnect the connector (A). 2. Remove VTC oil control solenoid valve B with the O-ring (C). cardiagn.com 2. All Removed Parts - Install 1. Install the parts in the reverse order of removal with a new O-ring. Coat the new O-ring with clean engine oil. Clean and dry the mating surface of the valv
  • Page 6683. Connect VTC oil control solenoid valve 2P (male terminals) (A) connector No. 1 to the battery positive terminal with a jumper wire. Connect VTC oil control solenoid valve 2P (male terminals) (A) connector No. 2 to the battery negative terminal with a jumper wire. 4. Measure the clearance of the v
  • Page 669VTC Oil Control Solenoid Valve Removal, Installation, and Test Intake Side (VTC Oil Control Solenoid Valve A) 1. VTC Oil Control Solenoid Valve A - Remove 1. Disconnect the connector (B). 2. Remove VTC oil control solenoid valve A with the O-ring (C). cardiagn.com 2. All Removed Parts - Install 1. I
  • Page 6701. Remove the turbocharger joint. 2. Disconnect the connector (A). 3. Remove VTC oil control solenoid valve B with the O-ring (C). cardiagn.com 2. All Removed Parts - Install 1. Install the parts in the reverse order of removal with a new O-ring. Coat the new O-ring with clean engine oil. Clean and
  • Page 671VTC Strainer Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions
  • Page 672Torque: N·m (kgf·m, lbf·ft) Replace cardiagn.com
  • Page 6731. Turbocharger Inlet Joint Pipe - Remove 2. VTC Strainer and VTC Filter - Remove Note for installation Coat the VTC filter with new engine oil. Clean and dry the mating surface of the VTC strainer. 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 674VTC Strainer Removal and Installation 1. Water Passage - Remove 2. VTC Strainer - Remove 3. All Removed Parts - Install cardiagn.com 1. Install the parts in the reverse order of removal.
  • Page 675VTEC Rocker Arm Test Special Tool Required Image Description/Tool Number Air Pressure Regulator 07AAJ-PNAA101 cardiagn.com VCM Air Adapter 070AJ-001A101 1. Cylinder Head Cover - Remove 2. VTEC Rocker Arm - Test
  • Page 6761. Rotate the crankshaft pulley clockwise. Make sure that the secondary rocker arm (A), the primary rocker arm (B), and the mid rocker arm (C) are separated and that the secondary rocker arm and the mid rocker arm should move independently: If the mid, primary and secondary rocker arms move together
  • Page 6776. With the specified air pressure applied, rotate the crankshaft pulley clockwise. The secondary rocker arm (A) should move together with the mid rocker arm (B) and the primary rocker arm (C): If the mid, primary, and secondary rocker arms move independently, remove the mid, primary, and the second
  • Page 678VTEC Rocker Arm Test Special Tool Required Image Description/Tool Number Air Pressure Regulator 07AAJ-PNAA101 cardiagn.com VCM Air Adapter 070AJ-001A101 1. Cylinder Head Cover - Remove 2. VTEC Rocker Arm - Test
  • Page 6791. Rotate the crankshaft pulley clockwise. Make sure that the intake secondary rocker arm (A), intake primary rocker arm (B), and the intake mid rocker arm (C) are separated and that the intake secondary rocker arm and the intake mid rocker arm should move independently: If the mid, primary and seco
  • Page 6807. With the specified air pressure applied, rotate the crankshaft pulley clockwise. The secondary rocker arm (A) should move together with the mid rocker arm (B) and the primary rocker arm (C): If the mid, primary, and secondary rocker arms move independently, remove the mid, primary, and the second
  • Page 681VTEC/VTC System Description - VTC Overview The VTC system makes continuous intake and exhaust valve timing changes depending on the engine speed, the engine load, and the vehicle speed. Construction cardiagn.com VTC Actuator The VTC actuator is composed of the vane, the lock pin, the pin spring, and
  • Page 682cardiagn.co
  • Page 683cardiagn.com VTC Oil Control Solenoid Valve To control the camshaft angle continuously, the VTC oil control solenoid valve controls oil pressure to the advance chamber/retard chamber of the VTC actuator according to a signal from the PCM. The solenoid valve has a strainer that to avoid foreign mater
  • Page 684Control The VTC system diagram is as follows. The PCM advances or retards the valve timing based on the data from various sensors, and performs feedback-control to the VTC oil control solenoid valves. cardiagn.com Operation Advance Rotation Operation When the advance chamber is charged with pressure
  • Page 685Exhaust Side (VTC Actuator B, VTC Oil Control Solenoid Valve B) cardiagn.com Retard Rotation Operation When the retard chamber is charged with pressured oil from the VTC oil control solenoid valve, the camshaft rotates to the retarded side. In case of the oil non-pressurized state (engine is stopped
  • Page 686Exhaust Side (VTC Actuator B, VTC Oil Control Solenoid Valve B) cardiagn.com
  • Page 687VTEC/VTC System Description - VTEC Overview This system improves fuel efficiency and reduces exhaust emissions at all engine speeds, vehicle speeds, and engine loads. The powertrain control module (PCM) switches the low and high lift cam depending on the engine speed and load in order to optimize th
  • Page 688cardiagn.com VTEC Rocker Arm The intake rocker arm is composed of the primary, the mid, and the secondary rocker arms. The inner side of the intake primary rocker arm and the intake mid rocker arm have a VTEC switching piston in each rocker arm. The inner side of the intake secondary rocker arm has
  • Page 689The rocker arm oil control valve is integrated with the rocker arm oil control solenoid and the valve. cardiagn.com
  • Page 690When the rocker arm oil control solenoid turns on or off depending on a signal from the PCM, the hydraulic pressure subjects the valve to an ON/OFF control. By switching the ON/OFF of the valve, the hydraulic pressure applied to the VTEC switching piston in the rocker arms is controlled. cardiagn.co
  • Page 691Operation At low engine speed cardiagn.com At low engine speed, the rocker arm oil control solenoid is turned off by the PCM. Oil pressure from the rocker arm oil control valve does not enter the intake rocker shaft. The primary and the secondary intake rocker arms are lifted by the low lift cam lob
  • Page 692cardiagn.com At high engine speed/high load operation At high engine speed, the rocker arm oil control solenoid is turned on by the PCM. Oil pressure from the rocker arm oil control solenoid enters the intake primary rocker arm via the intake rocker shaft, and it moves the VTEC switching piston in t
  • Page 693VTEC/VTC System Description Overview This i-VTEC system has a VTC for the intake valve (IN) control, has a VTEC and VTC for the exhaust valve (EX) control. VTEC and VTC system's typical operation and purpose are followings. Engine Speed and VTEC and VTC System Operation Purpose Load Condition VTEC (
  • Page 694Construction VTEC is composed of the VTEC camshaft, the VTEC rocker arm, and the rocker arm oil control valve. cardiagn.com
  • Page 695VTEC Camshaft: The exhaust camshaft is structured so that each cylinder has a separate low lift cam lobe and a high lift cam lobe. cardiagn.com VTEC Rocker Arm: The exhaust rocker arm is composed of the primary, the mid, and the secondary rocker arms. The inner side of the exhaust primary rocker arm
  • Page 696The rocker arm oil control valve is integrated with the rocker arm oil control solenoid and the spool valve, it is installed on the cylinder head. When the rocker arm oil control solenoid turns on or off depending on a signal from the PCM, the hydraulic pressure subjects the spool valve to an ON/OFF
  • Page 697By switching the ON/OFF of the spool valve, the hydraulic pressure applied to the VTEC switching piston in the rocker arms is controlled. cardiagn.com Rocker Arm Oil Pressure Switch: The rocker arm oil pressure switch is attached to the rocker arm oil control valve. It monitors the hydraulic pressur
  • Page 698Operation The hydraulic pressure from the oil pump and the rocker arm oil control valve is sent into the primary rocker arm and the secondary cardiagn.com rocker arm via each oil port on the intake rocker shaft to operate the VTEC system. VTEC LO: The rocker arm oil control solenoid is turned off by
  • Page 699cardiagn.com VTEC HI: The rocker arm oil control solenoid is turned on by the PCM. Oil pressure from the rocker arm oil control solenoid enters the exhaust primary rocker arm via the exhaust rocker shaft, and it moves the VTEC switching piston in the rocker arm. This causes the VTEC switching piston
  • Page 700cardiagn.com VTC Overview The VTC system makes continuous intake and exhaust valve timing changes depending on the engine speed, the engine load, and the vehicle speed. Construction VTC Actuator: The VTC actuator is composed of the vane, the lock pin, the spring, and the housing with the timing gear
  • Page 701cardiagn.com VTC Oil Control Solenoid Valve: To control the camshaft angle continuously, the VTC oil control solenoid valve controls oil pressure to the advance chamber/retard chamber of the VTC actuator according to a signal from the PCM.
  • Page 702The solenoid valve has a strainer that to avoid foreign material contamination. cardiagn.com
  • Page 703cardiagn.com Control The VTC system diagram is as follows. The PCM advances or retards the valve timing based on the data from various sensors, and performs feedback-control to the VTC oil control solenoid valves. Operation Advance Rotation Operation: When the advance chamber is charged with pressur
  • Page 704In case of the oil non-pressurized state (engine is stopped), VTC actuator B is locked in the most advanced position by the return spring and the lock pin. cardiagn.com
  • Page 705Intake Side (VTC Actuator A, VTC Oil Control Solenoid Valve A) cardiagn.com Exhaust Side (VTC Actuator B, VTC Oil Control Solenoid Valve B) Retard Rotation Operation: When the retard chamber is charged with pressured oil from the VTC oil control solenoid valve, the camshaft rotates to the retarded s
  • Page 706Exhaust Side (VTC Actuator B, VTC Oil Control Solenoid Valve B) cardiagn.com